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SMED, stands for Single-Minute Exchange of Die, is a theory and techniques for

performing setup operations in under ten minutes, i.e., in a number of minutes expressed

in a single digit. The SMED method was reolutioni!ed by Mr. Shingosince "#$% in

&apan. The concepts and techniques became aailable to other countries started around"#'( in )est *ermany and Swit!erland and in "#'+ in Europe and nited States.

oweer, not until "#%s, the SMED technique getting acceptace to companies outside

&apan.

Components of Lead Time

/n manufacturing, lead time was consided starting from design until delier the products

or serices to the customers. Thus, the lead time consists of the following time elements0

1roduct Deelopment 2Design3 4ead Time.

Sourcing 21urchasing3 4ead Time.

Manufacturing (Production) Lead Time.

5rder 1rocessing 4ead Time.

Distribution 4ead Time.

5ther 2e.g. decision ma6ing, coordination3 4ead Time.

7learly, 1roduction lead time is only a small portion of the whole lead time, but it is theonly component which is controllable by production function.

The production lead time can be further diided into0

8ueue Time 9efore 1rocessing.

Setup Time.

:un 21rocessing3 Time.

)aiting Time after 1rocessing.

Moe Time.

;mong these time elements, run timeis the only portion that adds alues to the products.

5thers can be considered as a waste.

Effects of Setup Reduction

SMED in SMS Mode

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Setup reduction may bring the following impacts to the shop floor0

4ot-si!e can be reduced.

elp to reduce inentory.

:educe the cost of setup labor.

/ncrease the capacity on bottlenec6 equipment. elp to eliminate the setup scrap.

:educe the potentail 8uality problems and obsolescence

Alternatives for Setup Reduction

SMED is not the only approach for reducing setup time. Some other alternaties are0

1roduction 1lanning - reduce the number of setups.

*roup Technology < cell foramtion - reduce the number of setups

Design Standardi!ation - reduce the number of setups.

se Standard Module - reduce the number of setups.

)or6 Simplification.

Mechani!ation or automation - an expensie option.

Procedures for Setup Reduction

SMED can be conducted according to the following steps0

". =orm the setup reduction team.>. 7onduct training and education.

?. Study the setup process 2e.g., use ideo tape3.

(. 7lassify setup operations into waste, internal setups 2/ED3, and external setups25ED3.

o )aste - 5peration which do not add alues to the setup.

o /nternal Setups - 5perations that can only be performed while the machine

is shut down.

o External Setups - 5perations that can be performed without shutting down

the machine.$. Eliminate the waste.

+. 7onert as many internal setups as possilbe to external setups.

o se standard insert module.

'. /mproe internal setups 2include ad@ustment3.

o se specially designed cart to organi!e tools.o se quic6-release fasteners instead of bolts and nuts.

o se stoppers to quic6ly position the @igs.

o se rolling bolsters instead of cranes.

o se oerhang mechanisms to handle heay @igs.

o se locating pins and holes 2soc6et3 to eliminate the ad@ustment.

o se standardi!ed die height.

. /mproe external setups.

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o ;pply isual control principles.

o se chec6list to aoid omission.

o se specially designed cart to help organi!e tools.

o 5rgani!e wor6place 2$S3 to reduce search.

#. Deelop the standard operating procedure 2S513.

"%. Ealuate the performance of setup reduction."". 1repare for the next setup reduction pro@ect.

Toolits for Setup Reduction

Many tool6its can be applied to help setup reductions. =or instance0

Aisual 7ontrol.

7hec6list.

Specially designed setup cart.

)or6place organi!ation 2$S3.

:ailed cart.

Standardi!ed baseplate and soc6et.

;ttachment plate.

5erhang tools.

8uic6 fasteners -- clamping cam, cran6, clamping 2loc63 leer.

Standardi!ed die height.

4ocating pins.

Stopper.