How do you identify and eliminate the root causes of setup variability and inefficiency in PDCA?

A sigla significa “Single Minute Exchange of Die”, traduzindo para o português, “troca rápida de ferramenta”, é uma das ferramentas de gest?o da produ??o enxuta do Lean, e na indústria exerce um papel muito parecido com o pit stop da Fórmula 1, atua reduzindo ao máximo o tempo gasto no processo de Setup das máquinas – que é uma atividade muito presente no cotidiano das fábricas, e demanda muito tempo dos operadores, trocadores, reguladores etc. é um período de prepara??o da máquina, utilizado para realizar ajustes e trocas de ferramenta de um processo para que possam entrar outros produtos na linha de produ??o.

SMED stands for Single-Minute Exchange of Die, and it is a set of techniques and principles aimed at reducing the time it takes to perform equipment changeovers or setups in manufacturing processes. The goal of SMED is to minimize the time required to switch a production line from producing one product to another, ideally reducing the changeover time to less than ten minutes. One step further is the O.T.E.D method.(one toch exchange of die)

The PDCA is a core component of Lean management and starts by identifying a problem's root causes and planning a strategy to tackle them. Initially, implement the approach on a modest scale to assess its problem-solving efficacy. Following this phase, gather and analyze data to estimate the strategy's success, questioning its outcomes and any discrepancies from expectations. If the strategy proves effective, broaden its application and formalize the new methods through updated documentation and training. If the strategy falls short of objectives, leverage the insights gained to refine the process with an adjusted plan. This continuous evaluation and adjustment cycle fosters continuous improvement in processes, products, or services.

O Ciclo PDCA é um método dividido em quatro etapas e oito passos, utilizado para solucionar problemas que n?o s?o facilmente visualizados na solu??o de problemas nas empresas e é uma das metodologias mais usadas. Assim como para a melhoria contínua de processos. Geralmente, esses problemas também já sofreram diversas tentativas falhas de solu??o. Dessa forma, suas finalidades s?o acelerar e aperfei?oar as atividades de uma empresa, por meio da identifica??o dos problemas, de suas causas e das possíveis solu??es.

The best way to reduce variability during first steps of a PDCA Cycle are: 1. Use Standard Operaring Processes based on SIPOC analisis 2. Implement Continuous Improvements techniques 3. Train your team 4. Reduce set up and lead times 5. Deploy visual reports available to all team members 6. Monitor frequently

When you conduct a workshop and analyze everything, you look for gaps, you look for potential for improvements, you are already conducting PDCA in a way, because the principle is like this. it is only important that every time we turn the circle, to standardize the matter, because otherwise we will be spinning in a vicious circle

The methods are interconnected and perfected. the benefit is a saving in time, and consequently money. In order to know the effect, it is necessary to repeat the matter over and over to achieve the desired result