SMED (Single-Minute Exchange of Die) Implementation Guideline

What SMED mean?

Single-Minute Exchange of Die (SMED) is a lean manufacturing technique developed to reduce equipment setup times to less than 10 minutes, thereby improving production efficiency and flexibility. This paper provides a comprehensive guideline for implementing SMED, including detailed steps and a case study to illustrate the process and benefits.

Introduction

SMED, pioneered by Shigeo Shingo, is aimed at minimizing downtime during equipment changeovers, allowing for smaller production batches and more responsive manufacturing processes. This guideline outlines the SMED methodology, its implementation steps, and a practical case study.

Step-by-Step SMED Implementation

Step 1: Preliminary Analysis

1. Identify Target Areas: Select machines or processes with significant setup times.
2. Form a SMED Team: Include operators, supervisors, maintenance staff, and process engineers.
3. Document Current Setup Procedures: Record the current setup process using video or detailed observations.

Step 2: Separate Internal and External Setup Activities

1. Define Internal and External Activities:Internal Setup: Tasks that can only be performed when the machine is stopped.External Setup: Tasks that can be done while the machine is running.
2. Record and Categorize Activities: Use video recordings and time studies to list all activities, classifying them as internal or external.

Step 3: Convert Internal Activities to External

1. Analyze Internal Activities: Identify tasks that could potentially be performed externally.
2. Develop External Alternatives: Find ways to complete these tasks while the machine is running.
3. Implement Changes: Modify processes to enable the external execution of these tasks.

Step 4: Streamline All Aspects of the Setup Operation

1. Simplify Internal Setup:Standardize tools and parts.Use quick-release mechanisms.Implement parallel operations.
2. Optimize External Setup:Prepare tools and materials in advance.Ensure all necessary components are easily accessible.
3. Reduce Adjustment Needs: Use pre-set gauges and eliminate trial-and-error adjustments.

Step 5: Document and Standardize the New Procedures

1. Create Standard Operating Procedures (SOPs): Document the new setup processes in clear, step-by-step instructions.
2. Train Employees: Educate operators and maintenance staff on the new procedures.
3. Implement Visual Aids: Use diagrams, checklists, and labels to reinforce the new processes.

Step 6: Continuously Improve

1. Monitor Performance: Track setup times and identify any deviations from the standard.
2. Gather Feedback: Solicit input from operators and other stakeholders.
3. Refine Processes: Continuously seek ways to further reduce setup times and improve efficiency.

Case Study: Implementing SMED in an Automotive Manufacturing Plant

Background

An automotive manufacturing plant was experiencing long setup times on their stamping press, averaging 60 minutes per changeover. This led to high inventory levels and reduced production flexibility.

Step 1: Preliminary Analysis

The plant selected the stamping press as the target area and formed a SMED team. They documented the current setup process using video recordings and detailed observations.

Step 2: Separate Internal and External Setup Activities

The team identified tasks such as die removal and installation as internal activities, while tasks like fetching tools and preparing materials were classified as external.

Step 3: Convert Internal Activities to External

The team analyzed internal tasks and determined that pre-positioning dies and tools could be done externally. They redesigned the workflow to allow these tasks to be completed while the machine was running.

Step 4: Streamline All Aspects of the Setup Operation

The team standardized tools and parts, implemented quick-release mechanisms for dies, and reorganized the workspace for better accessibility. They also developed a system for parallel operations, allowing multiple tasks to be performed simultaneously.

Step 5: Document and Standardize the New Procedures

The new setup process was documented in SOPs, and operators were trained on the updated procedures. Visual aids, including diagrams and checklists, were implemented to reinforce the new process.

Step 6: Continuously Improve

The plant monitored setup times, which reduced from 60 minutes to 12 minutes. Feedback from operators was gathered to identify further improvement opportunities, leading to additional refinements and a final setup time of 8 minutes.

Conclusion

Implementing SMED can significantly enhance manufacturing efficiency by reducing setup times and increasing production flexibility. By following a structured approach—separating internal and external activities, converting internal to external tasks, and continuously refining processes—manufacturers can achieve substantial improvements in their operations.