3What is SMED? Single-Minute Exchange of Die is one of the many lean production methods for reducing waste in a manufacturing process. It provides a rapid and efficient way of converting a manufacturing process from running the current product to running the next product.2
4SMED value to business3 Economic Order Quantity Historically maximize production count to keep unit overhead cost low.High production counts create inefficiencies in other areas.SMED allows smaller production runs while retaining low unit cost.SMED supports just-in-time inventory.
5Toyota background4 Shigeo Shingo - Toyota Production System, SMED Changing multi-ton precision dies on vehicle body transfer-stamping machines took anywhere from 12 to 36 hours to complete.By applying SMED Principles Toyota reduced changeover time to less than 10 minutes.Creating an EOQ of less than 1 car.
6SMED 8 techniques for consideration5 Separate internal from external operationsConvert internal items to external itemsStandardize the function, not the shapeEliminate fasteners or use functional clampsUse intermediate jigsAdopt parallel operationsEliminate adjustmentsUse mechanization
7SMED 7 Reduction steps6 Observation (A) Separation (B) Conversion (C) Simplification on internal (D) focus on fixingsStandardization of external activities (D) similar scale to internalDocumentationRepetition
8Key observations for improvement7 shortages, mistakes, inadequate verification of equipment causing delays and can be avoided by check tables, especially visual ones, and setup on an intermediary jiginadequate or incomplete repairs to equipment causing rework and delaysoptimization for least work as opposed to least delayunheated molds which require several wasted 'tests' before operating temperature to workusing slow precise adjustment equipment for the large coarse part of adjustmentlack of visual lines or benchmarks for part placement on the equipmentforcing a changeover between different raw materials when a continuous feed, or near equivalent, is possiblelack of functional standardization, that is standardization of only the parts necessary for setup e.g. all bolts use same size spanner, die grip points are in the same place on all diessignificant operator movement around the equipment during setupmore attachment points than actually required for the forces to be constrainedattachment points that take more than one turn to fastenany adjustments after initial setupany use of experts during setupany adjustments of assisting tools such as guides or switches
9SMED Techniques in action Separate internal from external operationsTools, tires, crew ready to goConvert internal items to external itemsCaptive wheel-nutStandardize the function, not the shapeEach crew has specialized taskEliminate fasteners or Use functional clampsSingle wheel-nutMinimal threadsUse intermediate jigsAlignment tape with position marksAdopt parallel operations4 teams – 4 tires, other activitiesEliminate adjustmentsPre-calibrated air gunsUse MechanizationAir guns with backupJacks
17Sources1Anonymous, “F – Pit Stop Record at Malaysian GP by Red Bull and Webber,” AutostradaTV2Anonymous, “Single-Minute Exchange of Die”3Ibid.45678Max Halliwell, “Red Bull Double Pit Stop Monaco 2011 – Unique Footage – Webber not amused…”9Anonymous, “Art of Pit Stop,” Infiniti Red Bull Racing10Anonymous, “The Shingo Prize”