Quick Changeover SMED

QUICK CHANGE OVERSingle

Minute

Exchange of

Dies

Changeover ti

me

Traditional setup

Single Minutes Exchange of Dies

SMED Process Steps

Ideas for Improvement

QUICK CHANGE

OVER

CONTENTS

INTRODUCTION

Mold ChangeColour Change

Mold change Inspect/Adjust

SetupTime

1st Piece Time(good or bad)

1st Good Piece Time

0

Last good part

The time elapsed between when the last good piece of

product A comes off and the first good piece of

product B starts.

Changeover time: Definition

Available time

Available operating time

Actual operating time

Effective Operating time

Breakdowns

Setup/adjustment

Idling/minor stoppages

Speed

Defects in process rework

Start-up losses

EQUIPMENT SIX BIG LOSSES

INTRODUCTION History : Land costs in Japan were very

high, therefore it was not feasible to store large inventories of vehicles

Developed by Shigeo Shingo( in the late 1950’s and early 1960’s) chief engineer of Toyota

Reduces the waste of inventory by creating shorter production runs that better align with customer demand

“A rapid and efficient way of converting a process from running the current product

to running the next product “

QUICK CHANGE OVERS

QUICK CHANGEOVER IN LEAN

TRANSFORMATION

TRADITIONAL VS

SMED

How long does it take to change the tire???

6 “Traditional” Setup Steps

Preparation Ensures that all the tools are working properly and are in the right location.

Extraction The removal of the tooling, raw material, and support equipment after the production lot is

completed.

Mounting The placement of the new tool, support equipment, and raw material before the next production lot.

Establishing Control Settings Setting all the process control settings prior to the production run.

First Run Capability This includes the necessary adjustments required after the first trial pieces are produced.

Setup Improvement The time after processing during which the tooling,

machinery is cleaned, identified, and tested for functionality prior to storage.

INTRODUCTION

SMED: Single Minute Exchange of Die

Concept that says all setups should and can take less than

10 minutes

OTED: One Touch Exchange of Die

Concept that says all setups should and can take less than

100 seconds!

What is “World-Class” in Quick Changeovers?

GOALS

The SMED Process

1 2 3 4 5

Reduce inventory Reduce batch sizes Reduce changeover time Reduce impact on equipment

utilization Improve quality after changeover Improve repeatability Improve throughput Improve flexibility

Observe and record

Separate internal and

external activities.

Convert internal

activities to external activities

Streamline all activities

Document internal

and external

procedures

THE SMED PROCESS

1. OBSERVE AND RECORD

We should always:

Notify the party to be observed ahead of time

Explain why we are conducting an observation We’re observing the activity not the person What we are trying to accomplish

Explain the possible benefits for them and the company

Review the observation with the individual Coaching Clarification

REMEMBER!!!

These activities are not conducted for the purpose of eliminating jobs or reducing

people!

Identify internal and external elements, waste/lost time, variances from the standard process

THE SMED PROCESS

2. SEPARATE INTERNAL AND EXTERNAL ACTIVITIES

All Setup Activities Run

III IE E EE Run

Externals Internals Run

ExternalsPost-setupexternals

Internal elements: operations that must be performed while the machine/process is stopped

External elements: operations that can be performed while the machine/process is running

THE SMED PROCESS3. CONVERT INTERNALS TO EXTERNALS ACTIVITIES

InternalsExternals Run





Eliminate adjustment

THE SMED PROCESS

How to convert externals to internals ?

Eliminate search-and-find work Arrange tools & materials beforehand Complete prep work before starting changeover Standardize settings Make visual marks vs. trial and error adjustments Eliminate trial runs Postpone “put away” work

THE SMED PROCESS

4. STREAMLINE ALL ACTIVITIES

Machine running

Machine running

Last good piece of product A

First good piece of product B

Total setup

Internal and external elements

Internal elements

Machine running

Machine running



Total setup

External elements External elements

Streamlinedinternal elements

Machine running

Machine running



Total setup

Streamlined External

elements

Streamlined Externalelements

BEFORE

AFTER CHANGE OVER

STREAMLINE

STREAMLINE INTERNAL PROCESS

Create Parallel steps – completed at the same time

Reduce complexity and eliminate waste Use functional fixtures and jigs

• one motion fasteners• levered or one-turn fasteners• interlocking wedge or slot

Eliminate adjustments• use angle and flat• use preset pins, guides, notches etc.

Eliminate need to leave the machine• Use POUS and water spider

STREAMLINEEXTERNAL PROCESS

Adopt functional standards Visual factory locations for

tools Color coding Standard set ups Checklists

THE SMED PROCESS

ADOPT QUICK DIE

CHANGEOVER ( QDC)

HARDWARE

THE SMED PROCESS

Create new process

• Document who will do what and when• Practice quick changeover (QCO) before doing it

Test new process• Run pilot of new process

• document steps of new process• time steps of new process• document improvement opportunities• videotape and look for additional opportunities

Document new process

• Create new work sheets that include all the steps of the new process• Get all needed approvals• Train all workers• Post the standardized work sheets (STW)

• Make adjustments, as needed• Re-test, if necessary

5. DOCUMENT INTERNAL & EXTERNAL PROCEDURES

WHEN SHOULD YOU AUTOMATE??

Criterion 1:

The operation has already been dramatically simplified

Criterion 2:

Begin with semi automation to achieve 80% benefit at 20% cost

Criterion 3:

The automation is cost-effective

IDEAS FOR IMPROVEMENT

Setup sheetPrintsSpecial instructions

GaugesSet blocksStop gauges

Special tools

SET-UP TOOL CARTS


SET-UP DIE CARTS

Documentation

Tools

Rollers

T urntable


Slot address labels

Slot address

Model Slide value

Part Line #Cover

Block gauge #

ORGANIZE & STORE IN PROXIMITY


Clamping height

Cut away

here

Add

spacers

here

STANDARDIZE CLAMPING HEIGHT


Springplate

Adjustingpin

Interior space(inaccessible)

Adjustingwedge

Adjustingscrew

Better

Linear gauge& pointer

Dial gauge

Better Still

Die

4-piece clamp

SpringDie heights vary

BolsterPlate

Socket wrench removes screwSocket head cap screw4

3

1

2


Die

L clamp

SpringStandardize clamp heights on dies

BolsterPlate

Nut is not removed for setup!

BEFORE

AFTERStreamlined 1-Piece Clamp

Before

After

Mold

Stopper

Camlock

Eliminate bolts


QUICK RELEASE CAM LOCK

TOGGLE LOCK DOWN CLAMP


DieBeforeBolster

After

Bolster

DieSlot

Top view

Side view1. Lift

2. Tighten

Bolt & Slot

Hinged Bolt

Centering Jig

Revised: 1703 2003 TBM Consulting Group, Inc. All rights reserved.

TBM

TBM

External Pre-Setup Checklist Core Machine # 5

All Items Pre-Setup 10 Minutes Before Setup

Initial When

Complete Pre-Setup Items Responsible

Person Initial When

Complete Pre-Setup Items Responsible

Person

Schedule shows next 3 setups

Supervisor

Air hose, both sides of machine

Setup Person

All wrenches at point of use (no tool boxes)

Setup Person

Pre-set for next tool, next unloader

Setup Person

All areas clear and ready for setup

Setup Person

Quick Changeover SMED

Business

Transcript of Quick Changeover SMED