SMED/Setup Time Reduction

What is SMED OR Quick change over?

SMED Meaning- SMED (Single-Minute Exchange of Die) is a lean manufacturing technique that aims to reduce the time it takes to switch between different processes or products. The technique was developed by Shigeo Shingo, a Japanese industrial engineer, and is based on the idea that changeovers can be broken down into two categories: internal setup and external setup.

Internal setup refers to activities that can only be performed when the machine is stopped, such as removing and installing tooling, adjusting settings, and checking dimensions.

External setup refers to activities that can be performed while the machine is still running, such as preparing materials, cleaning and inspecting equipment, and positioning fixtures.

The goal of SMED is to reduce the amount of time that is spent on internal setup activities while maximizing the amount of time that is spent on external setup activities. This is achieved through a series of steps:

smed is considered as one of the effective lean tool to implement and improve productivity

How does smed work:

Analyze the current setup process: The first step in implementing SMED is to analyze the current setup process and identify all of the activities that are involved in the changeover.
Separate internal and external setup activities: Once all of the activities have been identified, they are separated into internal and external setup activities.
Convert internal setup to external setup: The next step is to examine the internal setup activities and determine if any of them can be converted to external setup activities. This is done by identifying ways to perform the activity while the machine is still running or by using quick-release mechanisms or pre-assembled components.
Streamline the remaining internal setup activities: After all possible activities have been converted to external setup, the remaining internal setup activities are streamlined and simplified as much as possible.
Implement and improve: Once the new setup process has been developed, it is implemented and continually improved through ongoing analysis and refinement.

The benefits of SMED meaning include reduced changeover times, increased production capacity, improved quality, and reduced waste. The technique can be applied to a wide range of industries, including manufacturing, healthcare, service, and logistics.

SMED Benefit (Quick Change Over)

there are many benefits smed meaning. apart from the below mentioned it will alos reduce the six big lossses of oee

Reduce batch size:

SMED helps to reduce batch size by making it easier to switch between different products or processes quickly. This means that manufacturers can produce smaller batches of products more efficiently, which can result in reduced inventory costs, improved quality control, and increased customer responsiveness.

Increase flexibility:

SMED allows manufacturers to be more flexible in their production processes, as it enables them to switch between different products or processes quickly and efficiently. This means that manufacturers can respond more quickly to changing customer demands, which can lead to increased sales and improved customer satisfaction.

Reduce inline stock:

SMED helps to reduce the amount of inventory that is held in-line during the production process. This means that manufacturers can reduce the amount of inventory that they need to store, which can result in reduced storage costs and improved cash flow.

Reduce lead time:

SMED helps to reduce lead time by making it easier to switch between different products or processes quickly. This means that manufacturers can produce products more quickly and respond more quickly to customer orders, which can lead to increased sales and improved customer satisfaction.

Improve quality:

SMED can help to improve quality by reducing the amount of time that is spent on changeovers. This means that manufacturers can spend more time on quality control and inspection, which can lead to improved product quality and reduced defects.

Reduce waste:

SMED helps to reduce waste by minimizing the amount of time and materials that are wasted during changeovers. This means that manufacturers can reduce the amount of scrap and rework that is generated, which can lead to reduced costs and improved efficiency.

Increase capacity:

SMED helps to increase capacity by reducing the amount of downtime that is associated with changeovers. This means that manufacturers can produce more products in a given amount of time, which can result in increased sales and improved profitability.

Increase safety:

SMED can help to increase safety by reducing the amount of time that workers spend on changeovers. This means that workers are exposed to fewer hazards, which can lead to a safer working environment and reduced workplace injuries.

Reduce expenses:

SMED helps to reduce expenses by minimizing the amount of time and resources that are wasted during changeovers. This means that manufacturers can reduce their expenses and improve their profitability.

Set up error elimination:

SMED helps to eliminate errors that are associated with changeovers by standardizing the changeover process and making it more efficient. This means that manufacturers can reduce the risk of errors and improve their product quality.

Reduce trial run time:

SMED helps to reduce the amount of time that is spent on trial runs by making it easier to switch between different products or processes quickly. This means that manufacturers can reduce the amount of time that is spent on trial runs, which can lead to improved efficiency and reduced costs.

Increase machine work duration:

SMED helps to increase the amount of time that machines are working by reducing the amount of time that is spent on changeovers. This means that manufacturers can produce more products in a given amount of time, which can result in increased sales and improved profitability.

Where is SMED can be implemented?

SMED (Single-Minute Exchange of Die) is a lean manufacturing technique used to minimize the changeover time between different processes or products. SMED meaning can be implemented in various industries, including manufacturing, healthcare, service, and logistics.

In manufacturing, SMED meaning can be implemented in industries that involve frequent changeovers such as automotive, food and beverage, pharmaceutical, and electronics.

By reducing changeover time, manufacturers can increase production capacity and flexibility, reduce inventory, and improve customer responsiveness.

In healthcare, SMED meaning can be implemented in hospitals and clinics to reduce the time it takes to switch between patients or procedures. This can result in shorter wait times, increased patient satisfaction, and improved resource utilization.

In the service industry, SMED meaning can be implemented in businesses that provide services with high variability such as restaurants, hotels, and airlines.

By reducing the time it takes to switch between different services or products, businesses can improve efficiency, reduce waste, and increase customer satisfaction.

In logistics, SMED meaning can be implemented in warehouses and distribution centers to reduce the time it takes to switch between different products or orders. This can result in faster order fulfillment, reduced lead times, and improved customer satisfaction.

Overall, SMED meaning can be implemented in any industry that involves frequent changeovers, and can result in significant improvements in efficiency, productivity, and customer satisfaction.

What is SMED (Quick change Over)?

In general, SMED meaning is that (quick change-over) steps take place within one of two Set up: external setup and internal setup components. Internal steps happen while the equipment or process is stopped.

External steps occur while the equipment or process is running. Both are important in accomplishing SMED.

The Single Minute Exchange of Die (SMED) system is a theory and set of skills that make it possible to perform tool setup and changeover activity in under minutes, in the single-minute range.

SMED meaning was originally developed to improve die press and machine tool set-ups, but its principles apply to changeover time reduction in all types of activities and processes.

It is important to point out that it may not be possible to reach a single-minute range for all Setups, but SMED meaning does dramatically reduce Set up times in almost every case.

Why SMED

To do away with the wastes that end result from “out of control” strategies growing inventories and lead instances.
To advantage manage on gadget, material & inventory.
Follow manage techniques to do away with the Erosion of enhancements.
Standardize upgrades for protection of Standardize enhancements for the preservation.

SMED Implementation Plan

Step-1 Identified Area

In this step, the target area for the pilot SMED planning is selected. The ideal equipment will have the following feature:

Duration:- The changeover is long enough to have significant room for improvement, but not too long as to be overcome in scope (e.g. a one-hour
changeover presents a good balance)
Variation: – There is a large variation in changeover times (e.g. changeover times range from one to three hours).
Opportunities: – There are multiple opportunities to perform the changeover each week (so proposed improvements can be quickly tested).
Familiarity: – Employees familiar with the equipment (operators, maintenance personnel, quality assurance, and supervisors) are engaged and
motivated.
Restriction: – The equipment is a Restriction /stoppage these improvements will bring immediate benefits. If constraint equipment is selected,
minimize the potential risk by building temporary stock and otherwise ensuring that unanticipated downtime can be tolerated.

Once the target component t has been selected, record a baseline time for the changeover. Changeover time should be measured because of the time between the production of the last setup and the production of the first setup. Changeover times may for the time being improve as an easy result of observing the method.

Step-2 Identify Component

In this step, the group works together to identify all of the components of the changeover. The most successful way of doing this is to videotape the whole changeover and then work from the videotape to create an ordered list of components, each of which includes:

Description
Cost in Time

Component: A typical changeover will result in the component being documented

Man and machine: once the target component t has been selected, record a baseline time for the changeover. Changeover time has to be measured due to the time between the production of the last setup and the production of the first setup. Changeover times may also in the meantime enhance as an easy result of gazing the approach.

Another note: at the same time as videotaping the changeover have numerous observers taking notes. once in a while the observers will word things that can be missed on the videotape

Observe: Only observe – let the changeover take its normal course.

Step-3 Separate External Component

In this step, elements of the changeover process that can be performed with little or no change while the equipment is running are identified and moved “external” to the changeover (i.e. performed before or after the changeover). It is not unusual for changeover times to be cut nearly in half with this step alone.

Retrieval: Retrieval of parts, tools, materials, and/or instructions.
Inspection: Inspection of parts, tools, and/or materials.
Cleaning: Cleaning tasks that can be performed while the process is running.
Quality: Quality checks for the last production run.

The deliverable from this step should be an updated list of changeover elements, split into three parts: External Elements (Before Changeover), Internal Elements (During Changeover), and External Elements (After Changeover).

Step-4 Convert Internal Elements to External

In this step, the cutting-edge changeover process is carefully tested, with the aim of converting as many internal factors to external as possible.

This can result in a listing of elements that are applicants for further action. This list has to be prioritized so the most promising applicants are acted on first. Basically, this comes right down to acting a cost/gain analysis for every candidate detail:

Price as measured via the substances and exertions had to make the necessary changes.
Benefit as measured by the point so one can be removed from the changeover.

Develop training:- prepare components in advance (e.g. preheat dies in advance of the changeover)

Jigs:- Use replica jigs (e.g. carry out alignment and different changes in advance of the changeover)

Modularize:- Modularize equipment (e.g. replace a printer instead of adjusting the print head so the printer can be configured for a brand new part
range in advance of the changeover).

Adjust:- modify the system (e.g. upload guarding to allow safe cleaning at the same time as the technique is walking)

Step-5 Streamline Remaining Elements

In this step, the remaining Component is reviewed with an eye toward streamlining and simplifying so they can be completed in less time. The first priority should be given to internal elements to support the primary goal of shortening the changeover time.

As in the previous step, a simple cost/benefit analysis should be used to prioritize action on elements.

Release:- use quick-release mechanisms or other types of functional clamps.
Adjustment:- Eliminate adjustments (e.g. use standardized numerical settings; convert adjustments to.
Multiple fixed settings:- use visible center lines and use shims to standardize die size).
Motion:- Eliminate motion (e.g. reorganize the workspace).
Waiting:- Eliminate waiting (e.g. make first article inspection a high priority for QA).
Standardizing:- Standardize hardware (e.g. so fewer tools are needed).
Operations:- Create parallel operations (e.g. note that with multiple operators working on the same equipment close attention must be paid to
potential safety issues).
Mechanize:- Mechanize (normally this is considered a last resort).

Step to Implement SMED (Single Minute Exchange of Dies)

Identified the process

In this first step, the focal point vicinity for improving changeover instances is diagnosed. It desires to be a situation wherein:

The changeover is lengthy enough where there is room for development.
There has historically been numerous variance in the beyond in changeover instances.
The operation is achieved regularly.
All employees involved in the changeover system were trained and feature purchase-in for the change.
The system has been a bottleneck inside the general operation, which means adjustments will have a spot impact.

Identify elements

Once more, video usually is available in handy. Seeing how the method is being dealt with can assist perceive regions for improvement each detail of the procedure needs to be quantified through the quantity of time it takes as well as the value.

The technique is then mapped out through every person's detail, the ones related to each human and device sports.

Separate external elements

In this step, all factors of the operation that are external should be separated. This includes elements that might be currently internal but can be made external.

On every element, it should be asked: can this be performed even as the device or technique is going for walks? If so, it may be carried out before the real changeover takes place.

Convert internal to outside

As mentioned above, any detail that can be moved to the external needs to now be moved. Prioritize the listing so that the factors with the maximum capability impact on lowering time and value are acted on first.

This includes superior instruction on many factors. It also ought to involve reconfiguring equipment or making an investment in extra machinery that can handle an external detail at the same time as the primary process continues to be strolling.

Streamline

In this very last step, the internal factors must be simplified to take less time. Every single detail has to be taken into consideration. This also can contain new equipment or amendment to the present system to make changeovers run smoother and quicker. Also, preserve in mind to eliminate wasted motion or time spent ready – two of the fundamental regions of waste addressed in Lean.