Mastering SMED: Speeding Up Changeovers in Manufacturing

Single Minute Exchange of Dies (SMED) is a lean manufacturing methodology aimed at reducing the time it takes to switch from one process to another. While Dies are not used in every process, this concept still applies to many work environments. The goal of SMED is to perform changeovers in the shortest time possible and reduce the setup times associated.

SMED involves several key principles which we will explore in this blog post:

REAL WORLD SMED

Let’s look at a real-world example. A mid-sized company making automotive parts was struggling with long setup times, which hurt their production capacity and drove up costs.

Mapping: process map their current setup, realizing only 30% of tasks were done externally.
Separation: categorized tasks into internal and external and moved simple tasks like tool prep to external.
Conversion: Internal tasks optimized with quick-release mechanisms.
Streamlining: Remaining tasks were simplified with better organization.
Standardization: Detailed instructions and training sessions implemented.

The Results:
Setup time dropped from 60 minutes to just 15
Production capacity jumped by 20%
They saved $150,000 annually thanks to less downtime and higher efficiency.

Implementing SMED

Implementing SMED can transform a manufacturing process by providing less downtime, more flexibility, better quality, and boosted productivity.

But how exactly do we implement SMED into our manufacturing process?

Step 1: Identify the Current Setup Procedure

First things first – you need to know where you stand. Document your current setup process, from the last production run to the start of the next. Every little detail counts here. What tasks are involved? Who does what? How much time does each step take? It’s like mapping out a journey before planning the fastest route.

Step 2: Separate Internal and External Setup

Now, let’s get technical. Divide your setup tasks into two categories: internal and external. Internal tasks are the ones that require the equipment to be stopped, while external tasks can be done while the machine is running. Think of it as juggling – the more tasks you can do without dropping the ball (or stopping the machine), the better.

Step 3: Convert Internal to External Setup

Time to play detective. Look closely at your internal setup tasks and ask yourself: Can any of these be done externally? It’s all about finding creative solutions. Maybe you can pre-stage tools and materials, or use quick-release fasteners to speed things up. The goal? Minimize downtime and keep that production line humming.

Step 4: Standardize Setup Procedures

Consistency is key. Create standardized procedures for both internal and external setup tasks. Think of it as following a recipe – you want every setup to turn out just as perfect as the last. Develop checklists, visual aids, and other documentation to ensure everyone’s on the same page.

Step 5: Streamline Internal Setup

Time to trim the fat. Take a close look at your internal setup tasks and ask yourself: Is there a better way? Maybe you can eliminate unnecessary steps, or optimize tooling and equipment. It’s all about working smarter, not harder.

Step 6: Implement Quick Changeover Techniques

Get ready to level up. Introduce quick changeover techniques to supercharge your setup process. Pre-staging tools and materials, using modular setups – the possibilities are endless.

Conclusion:
SMED is a game-changer in the world of manufacturing. By reducing setup times, you can enhance efficiency, cut costs, and improve product quality. Sure, it takes some effort to get started, but the rewards are well worth it. Plus, you can dive into other lean methodologies like Kaizen, Value Stream Mapping, and DMAIC to keep the improvements rolling.

AUTHOR

Marcus Rosati

B.S. Industrial Engineering – Purdue University
B.S. Industrial Management – Purdue University

Lead Industrial Engineer for Process Improvement Projects

June 6, 2024

INDUSTRIAL ENGINEERING