How to Implement SMED : Steps and Phases

Presented by : Nikunj Rana

Stages Of SMED

Step 4Develop One Step Setup Training Plan

TOTA

L SE

T U

P T

IME

INT

ER

NA

L SE

T U

P T

IME

120 MINS

STAGE I

Segregate Internal External Elements

STAGE II

Convert some Internal Elements or parts of those to External Elements

STAGE III

Reduce times of residual Internal Elements

80 MINS

40 MINS

7 MINS

The SMED Process

Five Steps to Quick Changeover

4

One Step Set-up Implementation Plan

Separate Internalfrom External

Setup

Optimizing Setup ProcessesIntegrate Internal into

External Setup

Reduction of Setup Processes

ProgressiveEnhancement

s

Step 2Develop Specific

Implementation Plan

Step 3Develop Communication

Plan

Step 5Implement One Step

Set-up

Step 6Verification / Standardization

Step 1Develop One Step Setup Implementation Team

Step 4Develop One Step Setup Training Plan

Implementation TechniquesSeparate internal from external setup operationsConvert internal to external setupStandardize function, not shapeUse functional clamps or eliminate fasteners altogetherUse intermediate jigsAdopt parallel operations Eliminate adjustmentsMechanization

SMED Phases : Phase IInternal and external setup operations must be distinguished.• Internal setup operations can only be

performed when the machine is stopped. (Example: Mounting or removing dies)

• External setup operations can be conducted while the machine is operating. (Example: Transportation of tools and parts to where they are needed.)

SMED Phases : Phase II

SMED Phases : Phase III

SMED Phases : Phase IV

Streamlining of all aspects of setup operations.• Emphasis is on eliminating both

internal and external operations to reduce overall setup time. This involves investing in technology such as product redesign, new tooling, or automation.

Benefits of SMEDStockless production which drives capital turnover rates,

Reduction in footprint of processes with reduced inventory freeing floor space

Productivity increases or reduced production time

Elimination of unusable stock from model changeovers and demand estimate errors

Goods are not lost through deterioration

Ability to mix production gives flexibility

New attitudes on controllability of work process amongst staff

SMED Examples

SMED Examples

SMED Examples

For example: A slide clamp reduced the time required to load and unload parts to fixture. 2 hold-down clamps eliminated the need to tape parts during a glue-up operation. Set slide allows quick (temporary) alignment of 2 parts.

SMED Examples

SMED ExamplesSplit thread boltsHandlesToggle clampsU-shaped washers

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Make the tool part of the screw device -- you don’t need a tool, and this will save time in disassembling and reassembling the tooling and fixturing!

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Reduce the amount of screw turns and eliminate the tool!

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Thank You