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TRAINING, INSTRUCTION, METHODS, PRESENTATION AND LEARNING SMED METHODS FOR EVERYONE
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DO YOU
SMED?The 5 R Cycles to SMED Timed Processes
Created by Tom Curtis 2011Blog: www.onimproving.blogspot.comOther presentation on www.slideshare.netUnder Onimproving Email: [email protected] me on Twitter @onimproving
INTRODUCTION
SMED is a concept that came originally from Japanese Manufacturing Operations and the work of Shigeo Shingo. Companies faced a challenge in how quickly they could
change large metal presses over to the next stamping. This process could take days. Shingo found ways to slash this
number to mere hours and in some cases to minutes. SMED stands for single minute exchange of dies. This literally was to be able to make the change in under 10 minutes. SMED for us is the opportunity to take timed processes and find ways to reduce the time and pressure on what has to be
done while the stop watch is running. This has application in lots of places beyond the factory. What follows is a process
to helps us practice SMED. --Tom Curtis
THE 5 R CYCLES
Review Steps
Remove Steps
Reorder Steps
Reposition Steps
Replace Steps
REVIEW CYCLE
Walk the Process: What are all the steps? This becomes our Baseline and Standard
for Improvement. Document them.
1 2 3 4 5 6
Observation and thorough review reveal Hidden Factory.
Document Sequence and Content.
StartTime
EndTime
REMOVE CYCLE
Walk the Process: What steps are not needed? Remove them.
1 2 3 4 5 6
If a process has not been held to a Standard it may have extra steps.
StartTime
EndTimeX
Keep only required steps.
REORDER CYCLE
Walk the Process: What steps should be reordered?
Move them.
3 2 4 6 1 5
The original order may provide opportunities for improvement.
StartTime
EndTimeX
Improve the sequence.
REPOSITION CYCLE
Walk the Process: What steps could be done before we start
the clock? Shift them.
3 2 4 6 1 5
Moving Steps before the time starts shorten the time bound process.
StartTime
EndTimeX
Shift Steps out side of the timed process.
REPLACE CYCLE
Walk the Process: What steps could be combined or
improved? Kaizen them.
3 2 4 6 1 5
Kaizen will help us strengthen the required steps.
StartTime
EndTimeX
Improve the Steps that remain.
NewNew
BEFORE AND AFTER SMED
1 2 3 4 5 6StartTime
EndTime
3 5StartTime
EndTime
New 6&1
New 4
Before
After5 R Cycles
