SMED Stands for Single Minute Exchange of Die

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SMED

What is SMED?SMED stands for Single Minute Exchange of Die. The

SMED system is theory and set of techniques that make it

possible to perform equipment set up and changeover

operations in under 1 minutes ! in others "ords# in thesingle minute range. SMED "as originally developed to

improve die press and machine tool set$ups# but its

principles apply to changeovers in all types of process.

%t is important to point out that if may not be possible to

reach single minute range for all Set ups# but SMED does

dramatically reduce Set up times in almost every case.


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Why SMED is important for companies?

&ustomers today "ant a variety of

products in 'ust the quantities they need.

They expect high quality# a good price#

and speedy delivery SMED helps meetthese customer needs "ith less "aste by

making it cost ! effective to produce

things in smaller quantities# or lots.


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The trouble "ith large lot production()arge lot production has several disadvantages(

Inventory waste( storing "hat is not sold costs moneyand ties up company resources "ithout adding any

value to the product.

Delay( &ustomers must "ait for the company to

produce entire lots rather than 'ust the quantities acustomer needs.

Declining quality( Storing unsold inventory increase

the chance that it "ill have to be scrapped or

re"orked# "hich adds cost to the product.


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The Benefits of SMED:SMED changes the assumption that set ups can be done

quickly# they can be done as often as needed. Thismeans companies can make products in smaller lots#

"hich has many advantages(

le!i"ility: companies can meet changing customer

needs "ithout the expense excess inventory.#uic$er %elivery: small lot production means fe"er

customers "aiting time.

Better #uality: less inventory storage means fe"er

storage related defects. SMED also lo"ers defects byreducing Set up errors and eliminating trial runs of

the ne" products.


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&igher pro%uctivity: Shorter changeovers reduce

do"n time# "hich means a higher equipment

productivity rate.


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The "enefits of SMED for you

SMED also benefit you and also company

employee. *irst quicker set up support 'ob security

by strengthening the companies competitiveness.

%n addition SMED make daily production "ork go

smoother because(

Simpler set up results in safer change over "ith

less physical strain or risk of in'ury.

)ess inventory means less clutter in the "ork

place# "hich makes production easier and safer.Set up tools are standardise and combined "hich

means fe"er tools to keep track of.


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Basic Steps In a Set up 'peration()+reparation# after process ad'ustments# checking of

material and tools

*)Mounting and removing tools and parts

+)Measurements# settings and calibrations,)Trial runs and ad'ustments


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()-reparation. after process a%/ustments.

chec$ing of material an% toolsThis step ensures that all part and tools are "here they

should be and that they are functioning properly. ,lso

included in this step is the period after processing

"hen these items are removed and returned to storage#machinery clean and so forth.

%n a traditional set up# parts of the preparation step

are done after the machine is stopped. This step should

be done as external set up# "hile the equipment is still

running.


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*)Mounting an% removing tools an% parts

This step includes the removal of parts and tools afterone product is processed# and the attachment of the

parts and tools for next product.

-enerally the machine must be stopped to do this

step# so it is internal set up. This internal set up step

the actual changing over takes very little time

compared to the other steps.


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+)Measurements. settings an% cali"rations

This step refers to all the measurements andcalibrations that must be made in order to perform a

production operation# such as centring# dimensioning#

measuring temperature or pressure and so forth.

,lthough the equipment must be stopped for thisstep# the SMED system teaches "ays to do these tasks

quickly by preparing the equipment is running.


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,)Trial runs an% a%/ustments

%n the final steps of the traditional set up operation#ad'ustments are made after a test piece is machined.

The more accurate your measurements and

calibrations are in the previous step the easier these

ad'ustment "ill be.&orrect ad'ustment of the equipment is one of the

most difficult tasks in a set up operation. %n traditional

set up# the time needed for trial runs and ad'ustments

depends on personal skill.

%n a traditional set up the machine is not making

good products until this step is finished# it is


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considered part of internal set up. SMED teaches "ays

to eliminate this step completely# so that the machine

makes good products right after it is started up.

Steps in set up +roportion of set up time

before SMED improvements

()+reparation# after process ad'ustments# checking

of material and tools

*)Mounting and removing tools and parts

+)Measurements# settings and calibrations

,)Trial runs and ad'ustments

/

0/

10/

0/


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0nalysing your Set up operationsThe main reason traditional Set up operations takes

so long is that internal external Set ups areconfused. Many tasks that could be done "hile the

machine is still running aren2t done until the machine

is stopped.

The three stages of SMED are described

designed to simplify and shorten changeovers. 3ut

before you start applying SMED# you need a clear idea

of ho" you currently perform Set up operations and

ho" long each steps takes.


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The preliminary step# called a Set up analysis# "ill

help you ho" to implement SMED improvement on

your equipment. Set up analysis has three main steps(1$4ideotape the entire Set up operation focusing on

the hand# eye# and body movements of the person

doing the Set up. 5se the camera2s time and date

function if there is one.

6$Sho" the video to the Set up person and other

people involved "ith the equipment. ,sk the Set up

person to describe "hat he is sho"n doing. 7ave the

group share their thoughts about the operation.

$Study the video in detail# noting the time andmotions involved in each step of the Set up. 5se the


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video players pause and re"ind functions as needed.

,lso use a stop "atch if necessary.


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The three stages of SMED:

Stage (:separating internal 1 e!ternal Set upThe most important step in implementing SMED is

distinguishing bet"een internal and external Set up.

3y doing obvious things preparation and transport

"hile the machine is running# the time needed forinternal Set up# "ith the machine stopped# can usually

cut by as much as to 0 percent.


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Stage *:2onverting internal set up to

e!ternal Set up

*urther reducing Set up times to"ard the singleminuet range involves t"o important activities( 18 re$

examining operations to see "hether any steps are

"rongly assumed to be internal Set up# and 68 finding

"ays to convert these steps to external Set up.9peration can often be converted to external Set up by

looking at the true function.


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Stage +:Streemlining all aspects of the Set up

operation

To further reduce Set up time# the basic elements ofeach Set up are analysed in detail. Specific principles

are applied to shorten the time needed# especially for

steps that must be done as internal Set up# "ith the

machine stopped.


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Description of stage (:There are three techniques help us separate internal

external Set up tasks. These techniques are( usingchecklists# performing function checks# and improving

transport of die and other parts.

2hec$lists:

, checklist lists everything required to set up and runthe next operation. The list includes such items as(

Tools# specifications# and "orkers required.

+roper values for operating conditions such as

temperature# pressure etc. &orrect measurement and dimensions required for

each operation


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&hecking item of the list before the m:c is stopped

helps prevent mistakes that come up after internal set

up begun.

unction chec$s(*unction checks should be done "ell before Set

up begins so that repair can be made ifsomething does not "ork right. %f broken dies#

moulds# or 'igs are not discovered until test runs

are done# a delay "ill occur in internal Set up.

Making sure such items are in "orking order before

they are mounted "ill cut do"n set up time a greatdeal.


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Improve% transport of parts an%

Tools:

Dies# tools# 'igs# gauges# and other items needed foran operation must be moved bet"een storage areas

and machines# then back to storage once a lot is

finished. To shorten the time the machine is shut

do"n# transport of these items should be done duringexternal set up. %n other "ords# ne" parts and tools

should be transported to the machine before the

machine is shutdo"n for changeover.


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Stage *: 2onverting internal set up to

e!ternal Set up

%$,dvance preparation of conditions(,dvance preparation of conditions means getting

necessary parts tools and conditions ready before

internal set up begins. &onditions like temperature#

pressure# or position of material can be preparedexternally "hile the machine is running.;Ex. +re$heating of Mould or Material8


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%mplementing *unction standardisation( involves t"o

steps(1$ )ook closely at each individual function in your

set up process and decide "hich functions if any

can be standardise.

6$ )ook again at the functions and think about

"hich can be made more efficient by replacingthe fe"est possible parts.

;Exp.clamping *unction standardisation8


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Streamlining e!ternal set up:External set up improvement include streamlining

the storage and transport of parts and tools. %ndealing "ith small tools# dies# 'igs# and gauges# it is

vital to address issue of tool and die management.

=ou need to ask yourself questions such as(

>hat is the best "ay to organise these items?

7o" can "e keep these items maintained in

perfect condition and ready for the next

operation?

7o" many of these items should "e keep instock?


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Improving storage an% transport:

9peration for storing and transporting dies can be verytime consuming# especially "hen your company keeps a

large no. of dies on hand. Storage and transport can be

improved by marking the dies "ith colour codes# and the

location numbers of the shelves "here they are stored# the

shelves are also marked.


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Streamlining internal set up:Through improvement in internal setup operations are

next. These include implementing parallel operations#using functional clamps# eliminating ad'ustments# and

mechani


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+arallel operations divide the set up operation bet"een

t"o people# one at each end of the machine.

>hen set up is done using parallel operations# it isimportant to maintain reliable and safe operations and

minimi

SMED Stands for Single Minute Exchange of Die

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