Single Minute Exchange of Die

(SMED)Raghavendra ParadkarMurtaza DalalUzair PatelShamsher PathanNeha Jaiswal

MEANING OF A SET UP TIME

Study blueprints

Get tools and gauges

Select and secure Fixture

Mounting, adjustments, feeder

QA inspection, pilot run

Count the jobs produced

Remove tools, mountings, fixtures

Cleaning

LEAN MANUFACTURING

Reducing waste

Increasing productivity

Innovative practices

Inculcating good management systems

Continuous improvement

LM Techniques 5S System

Visual Control

SOPs

JIT

KANBAN System

Cellular Layout

Value Stream Mapping

Poka Yoke

Single Minutes Exchange of Dies (SMED):

TPM

Kaizen Blitz

SMED

“Applying Ingenious methods, to bring set up

time to less than 10 minutes”.

One-Touch Exchange of Die>>changeovers

less than 100 seconds

HISTORY

The concept arose in the late 1950s -1960s

Shigeo Shingo >> Toyota

Bottlenecks at car body-moulding presses

Long tool changeover times

Drove up production lot sizes

Direct impact on Productivity

OBSERVATIONS

Most difficult tools to change >>dies on the

transfer-stamping machines that produce

vehicle bodies

The existing process took from twelve hours

to almost three days to complete

IMPLEMENTATIONS

Place precision measurement devices on the

transfer stamping machines

Record the necessary measurements for each

model's die

Scheduling the die changes in a standard

sequence

Toyota cut the change-over time to less than 10

minutes per die

BENEFITS OF SMED

Reduce batch size

Reduce lead time

Reduce inventory

Reduce scrap

Increase efficiency

Increase flexibility

SMED in Toyota factory

SMED in Formula 1

MAINTENANCE

MAINTENANCE DEFINITION

“Maintenance is a set of organised activities

that are carried out in order to keep an item in

its best operational condition with minimum

cost acquired”.

cont….

The combination of all technical and

administrative actions.

Including supervision actions, intended to retain

an item in, or restore it to, a state in which it can

perform a required function

Repair or replacement activities

PLANT

MAINTENANCE

Reduce Breakdowns

Reduce Downtime

Improving Equipment Efficiency

Improving Inventory Control

Maximising Production

Optimising Resources Utilisation

Optimising Useful Life of Equipment

Minimising Energy Usage

Providing Budgetary Control

TYPES

Run to Failure Maintenance (RTF)

Preventive Maintenance (PM)

Corrective Maintenance (CM)

Improvement Maintenance (IM)

Predictive Maintenance (PDM)

BREAKDOWN MAINTENANCE

Repairs are made after the equipment is failed

Machine can not perform its normal function

anymore

Bring this machine to at least its minimum

acceptable condition

It is the oldest type of maintenance

WHERE TO USEThe failure of a component in a system is

unpredictable.

The cost of maintenance is lower than other activities of other types of maintenance.

Financial justification for scheduling are not felt

DISADVANTAGES

Poor and hurried maintenance

Safety issues for both workers and machines

Delay in production & reduces output

Direct loss of profit

Preventive Maintenance (PM)

“Prevention is better than cure”

“Stitch-in-time”

Locates weak spots of machinery and equipments.

Periodic/scheduled inspections

Minor repairs to reduce the danger of unanticipated

breakdowns.

FACTORS OF PM

Adequate staff in the dept.

Qualified and skills (ITI)

The right choice equipment.

The support from management

Planning and scheduling of PM programme.

The ability to properly apply the PM programme

Classification of PM

Routine maintenance

Running maintenance

Opportunity maintenance

Window maintenance

Shutdown preventive maintenance

ADVANTAGES

• Reduces break down & down time

• Less odd-time repair and reduces over time of crews

• Greater safety of workers

• Lower maintenance and repair costs

• Less stand-by equipments and spare parts

• Better product quality and fewer reworks and scraps

• Increases plant life

• Increases chances to get production incentive bonus

THANK YOU