SMED

Quick tool or process change

Objectives of SMED
1. Identification f i t 1 Id tifi ti of internal and external set-up l d t l t operations 2. Convert i t 2 C t internal set-ups t external l t to t l 3. Elimination of waste, optimisation of each operation 4. Tools and equipment check list and storage method 5. Procedural chart (standardised set-ups) ( p ) 6. Reduction of set-up time 7. 7 Improvements without big investments Only make what can be sold. Ideally produce only goods that h th t have already been ordered. l d b d d Shigeo Shingo SMED - Quick Tool Change

Definition of a Set-up

Set-up i S t is:

The time from the last good piece of Batch A to the first good p piece of Batch B.
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Definition of internal & external operations

INTERNAL can only be carried out when the machine or process has stopped EXTERNAL could be done whilst the machine or process is still running
External te a Before

Internal

External After

SMED - Quick Tool Change

Key to Remember Set-ups are roadblocks to flow...

We want to eliminate the hurdles

SMED - Quick Tool Change

Establish Priorities
M/C No. No 1 2 3 4 5 Set-up Time 2.5 2.0 3.5 1.5 0.5 05 M/C Time 0.5 2.5 1.5 2.0 3.0 30 1 piece 3.0 4.5 5.0 3.5 3.5 35 2 piece 3.5 7.0 6.5 5.5 6.5 65 5 piece 5.0 14.5 11.0 11.5 15.5 15 5

i.e. It depends on lot size & frequency of set-ups

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A Typical Set-up
min
60

Position adjust Prepare tools and fixtures

45

30

15

Search

1 SMED - Quick Tool Change 7

Set-up tricks

Bring together

Tools, gauges, accessories, information BEFORE AFTER

machine machine

Decrease walking time. Stop searching

SMED - Quick Tool Change

An Improved Set-up
min
60

Position adjust Prepare tools and fixtures Position adjust Search Prepare tools and fixtures
2 SMED - Quick Tool Change 9

45

30

15

Set-up tricks

Prepare tools ahead of time

SMED - Quick Tool Change

10

Set-up tricks

Reassemble (kits)

Tools, gauges, accessories, information

Preceding kit P di Kits distributor

kit 1 kit 2 kit 3 kit 4 kit 5 Next kit

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machine

Internal vs External
External Before External Before Internal External E ternal After

Internal

External After Aft

Convert as much internal work as possible to external Work

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A Further Improved Set-up

min
60

Position adjust Prepare tools and fixtures Position adjust Search Prepare tools and fixtures
2

45

30

15

Position adjust
3 SMED - Quick Tool Change 13

Set-up tricks

Standardise

b a
Shimming for standard heights

a
Use stops or centering grooves set positions

Select only the tools you need

Use checklist or standard operating procedure

SMED - Quick Tool Change

Use equipment readout for setting avoid human feel

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Set-up tricks

Reduce

Double up

Dont use adjustable tools dj t bl t l

Pear shape holes quick bold release

C Washers for i k l quick release

Minimise bolt lengths

Split threads
(1/3 turn locking)

Intermediate surface to avoid movement during l d i clamping i

15

SMED - Quick Tool Change

An Ideal Set-up
min
60

Position adjust Prepare tools and fixtures Position adjust Search Prepare tools and fixtures
2

45

30

15

Position adjust
3 4

Only place in production d ti

16

SMED - Quick Tool Change

The Three Tricks of Set-ups

1. Eliminate 2. Combine 3. S Simplify f

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17

What is TPE?
Total P d ti Eff ti T t l Productive Effectiveness (%) =
Availability Rate x Performance Rate x Quality Rate

How do we calculate that ???

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Total Productive Effectiveness (TPE)

breaks, meetings, planned maintenance breakdowns, setup, tool changes, start ups. 120 start-ups -120 min breakdowns, setup, tool changes, start ups. 120 start-ups -120 min minor stops, idling, speed loss, adjustments etc. j -280 min breakdowns, setup, tool changes, start ups. 120 start-ups -120 min minor stops, idling, speed loss, j adjustments etc. -280 min scrap, rework. -40 min

Availability Rate = 765/885=86%

Performance Rate = 485/765=63%

Quality Rate = y 445/485=92%

Working Time 1440 min 163%

Available Time 885 min 100%

Operating Time 765 min 86%

SMED - Quick Tool Change

Productive Time 485 min 54%

Effective Time 445 min 50%

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TPE is 50%

Observation and Analysis Method

Observe with a video

If there is no one on the screen = waste

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Four Stages of Set-up Reduction

Preliminary Stage St (CURRENT)

Internal and External are not Distinguished Separating Internal and External Set-up Converting Internal to External Set-up

External is done as internal (long set-up)

Stage 2

Set-up are reduced by 30% to 50% Simplify positioning, centring, fixing, adjusting. Use team to perform internal activities in parallel; Set-ups are reduced by 30% to 50% more. Analyse each element in detail and improve it. Less than 10 minutes.
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Stage 3

Stage 4

Improving each element of the Set-up

SMED - Quick Tool Change

Analysis steps
1. Identify the set-up 2. List every step 3. Measure the time required for every step 4. Distinguish between internal and external steps 5. Plot the current graph set-up time 6. Convert as many internal steps to external steps 7. Reduce the internal steps time 8. Reduce the external steps time 9. Plot the improved graph set-up time 10.Define the ideal set-up 11.Plot the ideal graph and strive toward it.

Graph
1 2 3 4 5 6 7

Current
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Analysis steps
1. Identify the set-up 2. List every step 3. Measure the time required for every step 4. Distinguish between internal and external steps 5. Plot the current graph set-up time 6. Convert as many internal steps to external steps 7. Reduce the internal steps time 8. Reduce the external steps time 9. Plot the improved graph set-up time 10.Define the ideal set-up 11.Plot the ideal graph and strive toward it.

Graph
EXT. INT. 1 2 3 4 5 6 7

Current
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Analysis steps
1. Identify the set-up 2. List every step 3. Measure the time required for every step 4. Distinguish between internal and external steps 5. Plot the current graph set-up time 6. Convert as many internal steps to external steps 7. Reduce the internal steps time 8. Reduce the external steps time 9. Plot the improved graph set-up time 10.Define the ideal set-up 11.Plot the ideal graph and strive toward it.

Graph
EXT. INT. EXT. INT.

1 2 3 4 5 6 7 1 3 4 6 2

7 8 8 Current Improved
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SMED - Quick Tool Change

Analysis steps
1. Identify the set-up 2. List every step 3. Measure the time required for every step 4. Distinguish between internal and external steps 5. Plot the current graph set-up time 6. Convert as many internal steps to external steps 7. Reduce the internal steps time 8. Reduce the external steps time 9. Plot the improved graph set-up time 10.Define the ideal set-up 11.Plot the ideal graph and strive toward it.

Graph
EXT. INT. EXT. INT. EXT. INT.

1 2 3 4 5 6 7 1 3 4 6 2

7 8 8 Current Improved 1 3 4 6 7 Ideal

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SMED - Quick Tool Change

SET-UP Checklist
Is everything set-up & on hand? ? Have tools been identified & organised/stored? Has unnecessary handling been eliminated? Have slots/grooves replaced bolting? Have new set-up procedures been written? Have setting standards & instructions been written? Has optimum run time to set-up time been determined? Has optimum number of set-up operators been determined?

Can C tools be changed i less than 10 mins? l b h d in l h i ?

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