How do you standardize and document your setup procedures and checklists using TPM and SMED?

1 Identify setup steps

The first step is to identify all the steps involved in your setup process, from preparing the materials and tools, to adjusting the settings and parameters, to testing the output and quality. You can use a video camera, a stopwatch, or a flowchart to record and analyze the sequence of actions and the time spent on each step. You should also classify each step as internal or external, depending on whether it can be done while the machine is running or not.

2 Separate internal and external steps

The second step is to separate the internal and external steps, and try to move as many internal steps as possible to external ones. This means that you should perform the tasks that can be done before or after the machine is running, such as preparing the materials and tools, measuring the dimensions, or cleaning the parts. By doing this, you can reduce the downtime and waste associated with stopping and starting the machine.

3 Simplify and standardize internal steps

The third step is to simplify and standardize the internal steps, and try to eliminate or minimize the variability and complexity of the tasks that have to be done while the machine is stopped. This means that you should use standardized tools and fixtures, such as quick-release clamps, preset gauges, or color-coded labels, to speed up the adjustment and alignment of the parts. You should also use standardized settings and parameters, such as pre-programmed modes, default values, or common units, to avoid errors and rework.

4 Document setup procedures and checklists

The fourth step is to document your setup procedures and checklists, and make them accessible and easy to follow for your operators and technicians. This means that you should use clear and concise instructions, diagrams, photos, or videos, to show the steps and the expected results. You should also use checklists to verify that each step is completed correctly and safely, and to record the time and quality data. You should update and improve your documentation based on feedback and best practices.

5 Train and empower your team

The fifth step is to train and empower your team to perform the setup procedures and checklists, and to identify and solve problems. This means that you should provide them with the necessary skills, knowledge, and tools, to execute the tasks efficiently and effectively. You should also encourage them to participate in continuous improvement activities, such as kaizen events, root cause analysis, or brainstorming sessions, to suggest and implement ideas for reducing setup time and waste.

6 Monitor and review your performance

The sixth step is to monitor and review your performance, and to compare it with your goals and benchmarks. This means that you should use key performance indicators (KPIs), such as setup time, cycle time, throughput, quality, or customer satisfaction, to measure and evaluate your results. You should also use charts, graphs, or dashboards, to visualize and communicate your progress and achievements. You should review your performance regularly, and celebrate your successes and learn from your failures.

7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?