Single Minute Exchange Single Minute Exchange of Dieof Die

"Reduce your changeover and adjustment times "Reduce your changeover and adjustment times from hours to minutes"from hours to minutes"

Colleen Murphy Colleen Murphy Reid NelsonReid Nelson Peter NatalePeter Natale Michael MillerMichael Miller

OutlineOutline

What SMED ISWhat SMED IS MethodologyMethodology Shingo PrizeShingo Prize Case StudyCase Study

What is SMED?What is SMED?

Single Minute Exchange of Dies is a Single Minute Exchange of Dies is a philosophy where the target is to philosophy where the target is to reduce all setups to less than ten reduce all setups to less than ten minutes. SMED helps achieve minutes. SMED helps achieve lower costs, greater flexibility, and lower costs, greater flexibility, and higher throughput. It is one of the higher throughput. It is one of the key factors allowing JIT to be key factors allowing JIT to be successful.successful.

“SMED = Exchange dies in less than 10 minutes”

Single Minute Means: necessary setup time is counted on a single digit.

Classic ChangeoverClassic Changeover

Steps to ChangeoverSteps to Changeover

1.1. Machine is stoppedMachine is stopped

2.2. Changeover operations happenChangeover operations happen

3.3. Machine will start againMachine will start again

– Changeover times causes Changeover times causes productivity lossproductivity loss

Dismount tools

Change tools Adjustments (machine stopped)

Trials

Breakdown of Changeover Duration

Four Steps to SMEDFour Steps to SMED

1.1. Suppress useless operations, convert Suppress useless operations, convert IS operations into ES IS operations into ES

2.2. Simplify fittings and tighteningSimplify fittings and tightening– minimize " turning " movements: they minimize " turning " movements: they

request several grasp-release motions! request several grasp-release motions! – fit at once, in a single motion fit at once, in a single motion – use blocks, jigs, templates use blocks, jigs, templates – standardize tools, types and size of standardize tools, types and size of

screws, nuts...screws, nuts...

33rdrd and 4 and 4thth Step Step

3.3. Work together! Work together! – Setup a racing pit teamSetup a racing pit team

4.4. Suppress adjustments and trials Suppress adjustments and trials – Get it right the first timeGet it right the first time– Use jigs or makeshift devices to Use jigs or makeshift devices to

avoid and detect errorsavoid and detect errors

Creator of SMEDCreator of SMED

Shigeo ShingoShigeo ShingoTimelineTimelineBorn 1909 in JapanBorn 1909 in Japan1930--Degree in Mechanical Engineering1930--Degree in Mechanical Engineering1943-48-Ministry of Munitions1943-48-Ministry of Munitions

–Air launched torpedo depth mechanismsAir launched torpedo depth mechanisms–Improved manufacturing operations by Improved manufacturing operations by 100%100%

1950-Forms first stage of SMED 1950-Forms first stage of SMED –Involves splitting a setup operation into Involves splitting a setup operation into internal and external set ups internal and external set ups

Timeline cont….Timeline cont….

1956-58—Worked for Mitsubishi 1956-58—Worked for Mitsubishi ShipbuildingsShipbuildings– Invents a new system for hull assembly of Invents a new system for hull assembly of

65,000 ton super-tanker65,000 ton super-tanker– Cut time from four months down to three Cut time from four months down to three

and than two monthsand than two months 1970-Originated SMED system at Toyota 1970-Originated SMED system at Toyota Wrote more than 14 booksWrote more than 14 books

– Including Toyota Production SystemIncluding Toyota Production System

MethodologyMethodology

SMED has Four conceptual phasesSMED has Four conceptual phases 1. Internal and external setup 1. Internal and external setup

operations must be distinguished.operations must be distinguished. 2. Internal and external setup 2. Internal and external setup

operations are separated. operations are separated. 3. Conversion of internal setup 3. Conversion of internal setup

operations to external setup operations to external setup operations. operations.

4. Streamlining of all aspects of setup 4. Streamlining of all aspects of setup operations. operations.

Phase 1Phase 1

1. Internal and external setup 1. Internal and external setup operations must be distinguished.operations must be distinguished.– a.       Internal setup operations can only a.       Internal setup operations can only

be performed when the machine is be performed when the machine is stopped. (Example: Mounting or stopped. (Example: Mounting or removing dies)removing dies)

– b.      External setup operations can be b.      External setup operations can be conducted while the machine is operating. conducted while the machine is operating. (Example: Transportation of tools and (Example: Transportation of tools and parts to where they are needed.)parts to where they are needed.)

Phase 2Phase 2

2. Internal and external setup 2. Internal and external setup operations are separated. operations are separated. – Once the identification and Once the identification and

separation occurs, the time the separation occurs, the time the machine must be shut down can be machine must be shut down can be reduced between 30% to 50%reduced between 30% to 50%

Phase 3Phase 3

3. Conversion of internal setup 3. Conversion of internal setup operations to external setup operations to external setup operations. operations. – This occurs either through This occurs either through

restructuring the setup procedure, restructuring the setup procedure, process innovation, or technology.process innovation, or technology.

Phase 4Phase 4

4. Streamlining of all aspects of 4. Streamlining of all aspects of setup operations.setup operations.– Emphasis is on eliminating both Emphasis is on eliminating both

internal and external operations to internal and external operations to reduce overall setup time. This reduce overall setup time. This involves investing in technology involves investing in technology such as product redesign, new such as product redesign, new tooling, or automation.tooling, or automation.

3 Types of Investment3 Types of Investment

Work Center InvestmentWork Center Investment– A one time expenditure that reduces A one time expenditure that reduces

setups for many or all products in a setups for many or all products in a work center.work center.

Product Level InvestmentProduct Level Investment– A one time expenditure of time or A one time expenditure of time or

money which has a limited effect. money which has a limited effect. (Example: the reduction of a single (Example: the reduction of a single product setup time.product setup time.

Investment cont…Investment cont…

Policy Level InvestmentPolicy Level Investment– Focuses on improving the Focuses on improving the

environment surrounding the setup environment surrounding the setup processesprocesses e.g., equipment reliability and e.g., equipment reliability and

capability, material quality, availability, capability, material quality, availability, and product designand product design

EX: scheduling policy designed to EX: scheduling policy designed to minimize setup timesminimize setup times

About the Shingo Prize

The Shingo Prize for Excellence in Manufacturing was established in 1988 in honor of Shigeo Shingo. The Prize promotes world-class manufacturing and recognizes companies that achieve superior customer satisfaction and business results. The philosophy of the Shingo Prize is that world-class business performance may be achieved through focused improvements in core manufacturing and business processes.

The Shingo Prize

The Shingo Prize Model has been developed as a "world class" model for manufacturing that incorporates much of the work of Dr. Shingo, but also incorporates best practices from other sources as well. The model, however, is not just a production model, but an overall systems model incorporating all manufacturing and business functions and processes.

The Mission of the Shingo Prize is to: Facilitate an increased awareness in the Facilitate an increased awareness in the

manufacturing community of excellent to world-manufacturing community of excellent to world-class manufacturing practices and techniques class manufacturing practices and techniques which can maintain and enhance a company's which can maintain and enhance a company's competitive position in the global marketplace. competitive position in the global marketplace.

Foster understanding and sharing of successful Foster understanding and sharing of successful core manufacturing and business improvement core manufacturing and business improvement methodologies. methodologies.

Encourage research in business and Encourage research in business and manufacturing processes and production manufacturing processes and production improvements by both the academic and improvements by both the academic and business practitioners.business practitioners.

Shingo Prize

•Identify and eliminate wasted motions and non-value-adding activities.

•Only the final turn on a bolt or screw adds value (by securing a die, clamping/unclamping work, and so on). •The interrupted screw (or interrupted thread) provides one means of clamping and unclamping something quickly. Artillery breeches have been sealed in this manner since the nineteenth century.

Ordinary bolt versus interrupted thread

High Performance Work System /Team Based Organization

                                                                

                                           

Advantages of Set-Up Advantages of Set-Up ReductionReduction

Reduction of change-over costsReduction of change-over costs Production of smaller lot sizes combined with an Production of smaller lot sizes combined with an

increased number of change-oversincreased number of change-overs Trial-runs are minimized or even become Trial-runs are minimized or even become

superfluoussuperfluous Urgent orders can be quickly producedUrgent orders can be quickly produced Improved productivity (increased efficiency, less Improved productivity (increased efficiency, less

waste, less machine defects)waste, less machine defects) Set-Up becomes easy, no special skills are neededSet-Up becomes easy, no special skills are needed Reduction or elimination of intermediate inventoryReduction or elimination of intermediate inventory Improved flexibilityImproved flexibility Reduction of inventory costsReduction of inventory costs

SMED is Geared For SMED is Geared For You You Operators - Machine-settersOperators - Machine-setters Group leaders, team leaders, supervisors, foremenGroup leaders, team leaders, supervisors, foremen Technical and maintenance personnelTechnical and maintenance personnel Employees of supporting servicesEmployees of supporting services

– Industrial EngineersIndustrial Engineers – R&DR&D – Purchase DepartmentPurchase Department – Marketing, SalesMarketing, Sales – Quality DepartmentQuality Department – Equipment Engineering and constructionEquipment Engineering and construction – Process EngineersProcess Engineers – etc.etc.

Case Study: BPACase Study: BPA

Butyl Polymers America is a unit of Butyl Polymers America is a unit of Exxon Chemical CompanyExxon Chemical Company

Won the Shingo Prize for excellence Won the Shingo Prize for excellence in 1991in 1991

Applied JIT and SMED to refining Applied JIT and SMED to refining process, although setups aren’t process, although setups aren’t typical.typical.

BPABPA

““Basically we took all of the JIT Basically we took all of the JIT technologies and reduced them to a technologies and reduced them to a theory– and then reconstructed the theory– and then reconstructed the theory for application within chemicals.”theory for application within chemicals.”– Raymond Floyd, BPA manager.Raymond Floyd, BPA manager.

BPABPA

Quick disconnects on Quick disconnects on both sides of chemical both sides of chemical processes for quick processes for quick changeover.changeover.

Mixed model Mixed model sequencing cycle, sequencing cycle, using different using different catalysts, vessels, catalysts, vessels, temperatures temperatures pressures etc.pressures etc.

100 different types of 100 different types of polymerspolymers

BPABPA BenefitsBenefits

– Cycle time reductionCycle time reduction Texas plant 65%Texas plant 65% Louisiana plant 39%Louisiana plant 39%

– Process time reductionProcess time reduction One process went from 30 hours to 2 hoursOne process went from 30 hours to 2 hours

– Smaller batch sizeSmaller batch size

BPABPA Other ImprovementsOther Improvements

– 50% reduction in total inventory50% reduction in total inventory– 30%-50% reduction in air emissions30%-50% reduction in air emissions– 18% decrease in energy consumption18% decrease in energy consumption

Other ContributorsOther Contributors– TPM- total productive maintenanceTPM- total productive maintenance– Employee EmpowermentEmployee Empowerment– JIT aspectsJIT aspects