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SMED Quick Changeover

SMED Quick Changeover is a process used to continually reduce the set-up and changeover times within the plant operations

Benefits:

  • Improves the inventory levels
  • Reduces the lead time- Helps achieve continuous flow

Changeover Time

It is the time elapsed between the last good piece off one production run and the first good piece off the next run

SMED look at activities required to perform the actual work and separates them in two:

– Internal Activities:

Must be performed while the machine is shut down (attachment and detachment, test run)

– External Activities:

Can be performed while the machine is running (preparation of dies, transfer of dies)

SMED Quick Changeover Implementation Steps

  1. Separate the internal and external activities
  2. Convert internal setup activities to external ones wherever possible
  3. Eliminate the need for adjustment
  4. Improve manual operations
  5. Improve equipment
  6. Monitor improvement

Detailed SMED Quick Changeover Steps

1. Separate the internal and external activities

  • Identify all activities involved
  • Separate activities into external and internal
  • Develop a method of completing all external activities prior to the change over

2. Convert internal setup activities to external activities

  • Pre-arrange jigs, tools, dies and materials
  • Maintain good operating condition for dies
  • Maintain tidiness in storage areas

3. Eliminate the need for adjustment

  • Adjustments account for 50 to 70 percent of the total internal setup time
  • Some initial adjustments may be required

4. Improve manual operations

  • Apply time and motion studies techniques
  • Video tape the change over process for team to analyze
  • Eliminate the activities not absolutely necessary
  • Eliminate the walking if possible
  • Improve equipment
  • Automatic adjustment
  • Invent tools for setup reduction
  • Modify equipment so that some setup activities can be performed simultaneously

5. Monitor Improvement

  • Create an Improvement Chart
  • Track the actual changeover time and compare it with the target