Single Minute Exchange of Die | SMED
Single Minute Exchange of Die (SMED) is a simple but powerful Lean technique for reducing waste in a manufacturing process. It is a systematic approach that enables organizations to dramatically reduce set-up time or changeover time. It provides a rapid and efficient way of changing the machine set-up in a manufacturing process from one product to another.
Single Minute Exchange of Die is also known as SMED, Quick Changeover, Set-up Reduction. It was pioneered by Mr. Shigeo Shingo since 1950 in Japan, but only became popular to the other part of the world in 1980s.
Use SMED to Reduce Set-up Time
The objective of SMED is to reduce the set-up time. Set-up time is the time elapsed at a work centre from when the last good part of the current run is completed until the work centre starts running the first good part of the next run. Long set-up time resulted in a reduced number of set-ups, larger batch sizes and larger buffering work-in-process inventories and poor process flow and performance. Since set-up activities add no marketable form, fit, or function to the product, they are by definition non-value adding. By reducing set-up time, more set-ups can be completed each day, batch size can be correspondingly reduced, flow can be significantly improved. All these improvement will help to improve manufacturing flexibility.
The 4 stages of Single Minute Exchange of Die (SMED)
Stage 1. Ensure that external setup actions are performed while the machine is still running,
Stage 2. Separate external and internal setup actions, ensure that the parts all function and implement efficient ways of transporting the die and other parts,
Stage 3. Convert internal setup actions to external,
Stage 4. Improve all setup actions.
Definition of Internal and External Activities
Internal activities are those that can only be performed when the process is stopped, while external activities can be done while the last batch is being produced, or once the next batch has started. Examples of external activities include pre-heating of raw material and preparation of tools before the machine stops.
Tips for implementing SMED technique
One of the best ways to see immediate result of the technique is to perform a Kaizen Event using SMED technique on a pilot machine. The Kaizen Event usually takes about 3 to 5 days and will repeat the 4 stages of SMED over several iterations. A good rule of thumb is to target 50% improvement for each iteration, and repeat the process until the target is achieved.
SMED as a Lean Pilot Project
Most people’s initial reaction to the quantum improvement brought about by SMED is disbelieved, followed by total acceptance and commitment to Lean transformation. Hence if an organization needs to gain some ground support and buy-in for its Lean implementation, a pilot project on SMED can be a good head start that will gain good momentum.
Related pages that you may be interested in:
- Lean
- Value Stream Mapping | VSM
- Lean Implementation Tips
- 5S
- Lean Office
- Total Productive Maintenance | TPM
- Kaizen Event
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