SMED MANUAL

SMED MANUAL

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 SMED MANUAL
Table Contents

S.No. Description Page No.

01 Terminology Definitions 2

02 Definition related to SMED 3

03 Methodology 4

How to Start SMED ( Step by Step

04 5-14
Approach)

05 Learning & Benefits 15

Terminology Definitions
S.No. Terminology Definition
1 TWS TPM World Services
2 SMED Single minute exchange of Die
3 ECRS Eliminate, Combine, Reduce, Simplify
4 Contd. Continued
5 PDCA Plan-Do-Check-Act
6 VTR Video tap recording
7 S.O.P Standard Operating Procedure
8 QCO Quick Changeover

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 SMED MANUAL
SMED Definition:
SMED is a tool or set of techniques that make it possible to perform
equipment setup and changeover operations in fewer than 10
minutes – in other words, in the single-minute range.
It is a process of reducing changeover (setup) time by classifying
elements as internal or external to a machine's operating time and
then converting the internal elements so they can be done externally
(while the machine continues to operate).
Importance:
It provides a rapid and efficient way of converting a manufacturing
process from one product to the next. SMED is also often referred
to as Quick Changeover (QCO). Performing faster changeovers
is important in manufacturing, or any process, because they make
low-cost, flexible operations possible.
Scope:
SMED principles can be used and applied in almost any operation
or process. Ex. Machining shop, Casting shop, Assembly Line etc.
Internal Activity:
Internal activity is the activity which is involved during the machine
running condition for Product X. So if we want to work on
internal activity we have to stop the machine
External Activity:
External activity is the activity which is not involved during the
machine running condition for Product X. So if we want to work
on external activity we have not required stoppage of the machine
Series Activity:
Series activity is the activity which is involved during the setup
process and it means it has to do one by one (Sequential pattern)

Parallel Activity:
Parallel activity is the activity which is involved during the setup
process and it means two activity has to do in same time
(Simultaneously  pattern)
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 SMED MANUAL

SMED METHODOLOGY:
SMED principles can be used and applied by following 10 steps
approach as we have given below. For understanding point of view
we had given example story for your ready reference purpose

STEP-1 Prioritization of Plant Level Losses

STEP-2 Selection of the Theme & Team Formation

STEP-3 Data Collection & Stratification for bottleneck identification

STEP-4 Selection of Machine for Set-up Reduction

STEP-5 Videography

STEP-6 Analysis of Videography by Dividing into activities

Split the activities into Internal ,External, Series

STEP-7
Do ECRS for internal, External & Series activities

STEP-8 Do the Kaizens

STEP-9 Evaluate the Results

NO
Is the target met

YES
STEP-10 Standardization & Horizontal Deployment

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 SMED MANUAL

HOW TO START SMED PROJECTS:

STEP-1: Prioritization of losses :
Shop level down time is analyzed by Pareto principle as shown and
needs to take Highest loss for reduction purpose which is linked to KK
Pillars

STEP-2: Theme Selection

Theme has been selected from Loss Pareto and found that setup
change loss is the 2nd highest loss for KK pillar . So we worked on the
setup time reduction project by using SMED concept

Team Formation
We need to defined a Cross functional team by using below given
members from different departments and need to declare a team
leader for the project

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 SMED MANUAL
STEP- 3: Data Collection & Stratification of data :
We need to collect setup loss data from production MIS and have to
analyzed Setup time data Line wise or Machine wise as shown below.
Set up data collection
1. SET UP & ADJ LOSS – 2. SET UP & ADJ LOSS –
UNIT WISE PARETO – YEAR 2015-16 LP LINE WISE PARETO – YEAR 2015-16

STEP-4: Selection of Machine for Set-up reduction:

As on the above trend, we analyzed & found that in LP 1 Assy Line
setup time is more than all other lines. On Further machine wise
analysis we found Mig welding, Calibration & 45 T Press Setup time
were more than 20 mins and other machines were on 20 mins so we
decided to reduce these machines setup time up to 20 mins. First we
have done on Mig welding machine and based on the same concept
further planned to do on the other machines.
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 SMED MANUAL
Target Setting
We need to fix the target for setup time reduction phase wise to
achieve the target by continue setting the next level target for setup
time reduction by using PDCA approach till the SMED achieved
Set up Change Time Reduction Target
50
45
45 First Phase
Set up time in Minutes
Second Phase
40 55%
55% Reduction
Reduction
35
30
25
20
20
15
10 9
5
0
Previous (FY2012- Target (Jun-2013) Target (Sep-2013)
13)

STEP-5: Videography Activity

We need to do videography of setup time at the selected machine with
consideration of each and every activity involved during the setup time
as common practice followed by the people

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 SMED MANUAL
STEP-6: Analysis of videography Activities
Here we need to do analysis of videography of setup time by splitting
time into activities so that individual activity time can be noticed and
try to identify the waste time in the internal ,external & series activities

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 SMED MANUAL
STEP-7: Activities split up into Internal & External
Here we need to splitting the setup time into internal & external
activities and parellely identify the time consumed in each category of
activities Activity Split up
No. of Activities

25 20
20
15
10
5 3
0
Internal External

Time Consumed Activities wise

50 42.79
Time in Minutes

40
30
20
10 2.21
0
Internal External

Time Consumed Activities wise

Time in Minutes

20 16 15.07
15 11.32
10
5 2.13 0.37
0
Adjustment
Removal

Searching

Fixting
Cleaning

Cleaning & Searching Time = Needs to eliminate

Target for
Activities Fixing & Removal Time = 50% Reduction
Adjustment & Other Time = 50% Reduction
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 SMED MANUAL
Do ECRS for Internal & External Activities
Now we need to think how many activities can be convert from
internal to external , Series to parallel and then on the rest activity we
needs to apply ECRS tools to reduce set up time.

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 SMED MANUAL

Contd……….

Activity Convert from Internal to External

Internal Activity Conversion External Activity Conversion

21 5

No. of Activities
No. of Activities

20 4
20 4

19 3
19 3

18 2
Before After Before After

Time Saved thru ECRS Tools

20.00 18.27
18.00
Time in Minutes

16.00
14.00
12.00
10.00
8.00
6.00 4.40
4.00
2.00 0.33 1.07
0.00
Eleminate Combined Reduce Simplify

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 SMED MANUAL
STEP-8: Kaizen Implementation
We have done some Kaizen for set up time reduction which are
shown below.

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SMED MANUAL
Contd……….

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 SMED MANUAL
STEP-9: Result Monitoring
Here we need to monitor the result of Setup changeover time for few
day so that it could be in practice by shop floor people

Set up Change Time Reduced 54 %

Reduction
50 45
Time in Minutes

40
30
20.9
20
9
10
0
Before After Future Plan

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 SMED MANUAL
STEP-10 Standardization & Horizontal deployment

 Drawing are updated according to improvement done

Fixture sheet & tooling sheet are also updated after the kaizen is
successfully implemented
 For Set up time reduction SMED resource matrix made for
horizontal deployment of same concept
 Setup time S.O.P revised
 Kaizen are horizontal deployed across other machine

Learning & Benefits

 Production increased by 3.5% of available time.
 Inventory carrying cost reduced due to smaller production batches.
Space saving to keep less inventory .

THANKS FOR YOUR VALUE

ADDITION TO COMPANY

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