Single Minute Exchange of Die

Reema Mangtani PG14063

Simran Jain PG14074Deepak Nadar PG14094Frahvak Dumasia PG14095Chaitra Mhatre PG14101Gaurav Sonwani PG14117

Team Members

Introduction• Term used to represent the Single Minute Exchange of Die or setup time that can be counted in a single digit of minutes

• Successful implementation of SMED and quick changeover is the key to a competitive advantage for any manufacturer

• Effective SMED programs identify and separate the changeover process into key operations: Internal and External

How Can SMED Help Any Organization• Reducing downtime associated with the changeover process

• Reducing the waste created during startup

• Accelerate progress: Focus on people first

History

Developed by Shigeo Shingo( in the late 1950’s and early 1960’s) chief engineer of Toyota

• Shigeo Shingo was a Japanese industrial engineer and father of SMED

• He developed SMED while working for Toyo Industries in 1950

• He sought to eliminate bottlenecks by looking at changeover operations on large presses

• Shingo helped improve Mitsubishi Heavy Industries productivity by 40%.

• In 1969, Shingo continued to perfect the SMED system at Toyota Motor Corporation’s main plant

Changeover time size Process time

per itemOperation

time Ratio

8 hours 100 1 min 5.8 min 480%

8 hours 1,000 1 min 1.48 min 48%

8 hours 10,000 1 min 1.048 min 4.8%

Transformation

How long does it take to

change the tire???

Implementation/Working of SMED

• Step One – Identify Pilot Area

• Step Two – Identify Elements

• Step Three – Separate External Elements

• Step Four – Convert Internal Elements to External

• Step Five – Streamline Remaining Elements

Implementation Techniques Of SMED1. Separate internal from external setup operations.

2. Convert internal to external set-up

3. Standardize

4. Use clamps and “one-touch” fasteners

5. Use intermediate jigs

6. Adopt parallel operations

7. Eliminate adjustments

8. Mechanization: This should be used as the last resort

Benefits of SMED• Lower manufacturing cost

• Smaller lot sizes

• Improved responsiveness to customer demand

• Lower inventory levels

• Smoother startups

Practical Use of SMEDDID YOU KNOW?

10 min/day of downtime is more than one week per year of lost production

Surely you can save more than 10 minutes each day

What is a week’s production worth?

Some effective techniques: Visual Controls: Effective communication in a merchandising department

Order status Merchant responsible Stage at which the order is

Purpose: To make daily follow up checklists‐ For the dependant departments to know the process status and change their plan

accordingly

Practical Use of SMED

Checklist: Questionnaire placed near the machine to be checked before each setup process

Check panel : Next to the machine to make available all the tools at the required time

Parts and tools transportation improvements: Transportation from the warehouse to the work area carried out before the exchange begins

Endless material method: In a rolling mill or on packing machines End of a reel is welded or tied to the beginning of the following one

Practical Use of SMED

Tools duplication : It is possible to prepare the next two containers Eliminates the need of removing and placing the containers again

Remote Control: A worker had to go from the third floor to the basement every time a valve

needed to be turned on or off Replaced the manual valve with a remote-controlled electric valve Effectively gave the plant 4 weeks of additional production time per year, at a cost

of less than $500

Practical Use of SMED

Formula 1 Pit Stop Changing tyres and refuelling goes lightning fast

Practical Use of SMED

Cruise Ship Dock and disembark some 3,000 passengers, luggage and take on

3,000 new ones

Restock tons of food and supplies

Perform necessary maintenance to the ship

Sail again all in the course of a few hours

Equipped with specially designed devices and a very well trained crew

Practical Use of SMED

Stored with a purposeFiremen in the fire station sliding down fire polesSet up of pants and boots to slide in quickly

Practical Use of SMEDFire Fighters

Conclusion• SMED is an ideal tool which can be used to reduce the changeover time/set-up time in many industries

• It increases the flexibility of the company to produce the right number of products

Single-Minute Exchange of … Cocktail?!

Weblography• http://en.wikipedia.org/wiki/Single-Minute_Exchange_of_Die

• http://www.vorne.com/learning-center/smed-quick-changeover.htm

• http://www.leanproduction.com/smed.html

• http://www.makigami.info/cms/smed

• http://www.processexcellencenetwork.com/business-process-management-bpm/articles/single-minute-exchange-of-dies-smed/