How can you apply the SMED methodology to reduce setup times?

1 Identify setup activities

The first step is to identify all the activities involved in your setup process and classify them into two categories: internal and external. Internal activities are those that can only be done when the machine or process is stopped, such as removing and installing tools, adjusting settings, or testing the product. External activities are those that can be done while the machine or process is running, such as preparing tools, materials, or instructions, or cleaning the work area. You can use a video camera, a stopwatch, or a checklist to record and measure your setup activities.

2 Separate internal and external activities

The second step is to separate as many internal activities as possible and convert them into external activities. This means that you should perform them before or after the machine or process is stopped, not during the setup time. For example, you can prepare the tools and materials in advance, use standardized fixtures and clamps, or use quick-release mechanisms to speed up the removal and installation of tools. You can also use visual aids, such as labels, marks, or colors, to simplify the instructions and settings.

3 Streamline internal activities

The third step is to streamline the remaining internal activities and make them as efficient and error-proof as possible. This means that you should eliminate any unnecessary or redundant actions, simplify the procedures and motions, and reduce the variability and adjustment time. For example, you can use common tools and methods, eliminate trial runs and fine-tuning, or use poke-yoke devices, such as sensors, guides, or locks, to prevent mistakes and defects.

4 Streamline external activities

The fourth step is to streamline the external activities and make them as smooth and coordinated as possible. This means that you should optimize the flow and layout of the work area, reduce the distance and movement of materials and tools, and synchronize the tasks and roles of the workers. For example, you can use carts, racks, or conveyors to transport the materials and tools, use parallel processing or teamwork to perform multiple tasks simultaneously, or use standard work sheets or checklists to ensure consistency and quality.

By applying the SMED methodology, you can reduce your setup times significantly and enjoy the benefits of lean manufacturing. You can also apply the same principles to other types of changeovers, such as product design, order processing, or customer service.