SMED is stand for Single Minute Exchange of Die. SMED is used in place where is frequent change over of tools or there is any frequent job change over on machine or production line.
As name suggested single minute exchange of Die, tool is not change in one minute but change over time is in single digit i.e. less than 10 minutes.
Exchange of die or tool in less than 10 mins, mean there should be only done through only one changeover on the machine during continue production.
The SMED is a principle of Lean Manufacturing, which tell us to eliminate waste in the manufacturing process which help us to increase production & profitability of the organization. Similarly SMED also reduce changeover time from the process and increase available time for manufacturing, which in turn increases the production of the company. The changeover time reduce the production in the process, i.e uneven flow of production which is one of the waste out of three waste of Lean Manufacturing, this one is Mura.
SMED is long history started by Ford Motors in 1900s to reduce setup change over technology. SMED is developed by Japanese industrial Engineer Mr. Shigeo Shingo, who also invented Poka-Yoke. He helped Industries to reduce Setup time for more than 90%.
Ten Benefits of SMED:
As changeover time reduce, which increase profitability.
Increase the available time of the machine.
As change over time is fast, company may work on the concept of JIT.
Reduce inventory cost.
Down time of the machine will reduce.
SMED is best when there is frequent changeover of jobs.
No need keep inventory for longer time.
High skill of manpower is also not required.
Flexibility in production line increase.
Less error in tool changeover as step up is already done and only single tool changeover to be done.
Once we know about the benefits of SMED, but before implementing the SMED, we must study or search for the following things:
Least efficient process or processes
Bottleneck machine of the process
Machine with frequent changeover of the job.
Process where changeover time is maximum.
High skill is required for changeover.
Implementing SMED
As now we have identified the process or machine where we have to implement SMED. To implement SMED in the process we have to perform following task / steps:
STEP1: Identify Pilot Area.
STEP2: Identify Internal & External Element
STEP3: Convert Internal Element into External Element
STEP4: Streamline Internal and External Element
STEP1: Identify Pilot Area:
First step to implement the SMED in the organization is to pick a process or area with the longest changeover time. It is also important to get the confidence of the employee to implement the SMED. Give training and benefits about SMED to employees of the organization, so that they get motivated and give their best to implement SMED.
STEP2: Identify Internal & External Element:
Once our Pilot Area is identified, now it is time to identified internal and external elements of the process where changeover is maximum. It is very important to understand the complete process and good knowledge of all tools or parts that are involved in changeover.
Some organizations do video recording to the complete process and sit with SMED team to understand about the process and record the time taken to perform each task.
Before we go further, we must understand what internal element and external element is:
Internal Element: Any changeover processes that is performed while machine is stop.
External Element: Any changeover processes that can performed while machine is running.
Make a list of all changeover process divide them as Internal Element, External Element before changeover and External Element after changeover.
STEP3: Convert Internal Element into External Element
The main aim or focus point of SMED is seen in this step, i.e. convert Internal element into external element. SMED must focus how internal element convert into external element. SMED team must focus on all changeover components and analysis and try to make components changeover can take place externally, that is when machine is running component change over can take place. Important question is, how to make internal changeover to be convert into external changeover. This can be done using following techniques:
Make the list of all the parts and collect them all before actual changeover take place.
Plan to make any device or fixtures where parts can be assembled externally, which can directly fit into machine.
If required, modification can be done at machine also so at tool changeover will become easy.
Modification can be done in the tools also so that they can be assembly externally and fitted internally within minute or so.
Most importantly asked the operators for the ideas related to convert internal into external element as they spend their maximum time with the machine.
This step will take maximum time during implementing SMED. Now change over list that we prepared during the Step2, should be revised. Here we can find that good amount internal element is converted into external Element.
One thing to keep in mind is to take care of the Cost of changeover, Changeover cost must not increase while converting Internal Element into External Element.
STEP4: Streamline Internal and External Element
As our Internal element and external element is changed, now it is important to streamline the internal elements. SMED team must focus to reduce the changeover time of internal element, this will help us to reduce the further setting changeover time. Team must give more importance to Internal element than external element. Work is done to simplify the internal changeover process, so that change over time will reduce.
As all the steps are completed, now SMED team must prepare new work instruction for the new changeover the process, this must also include new internal and external element.
During and after implementation of SMED into organization, following points to be take care:
After implementing the SMED process it is important that at least 20 % of production is increased. If not, then then rethink about SMED and focus on TPM.
After implementing the SMED process, measure the changeover time, and compare time before and after the SMED implementation.
Cost of SMED implementation should not be greater than production gain after SMED implementation.
Proper documentation is to be prepare and Work instruction is to made after SMED implantation.
After Implementation of SMED, give proper training to employees about new changeover process. It is also important to motivate the down the line about new process, so that new SMED process is adapted easily.
Limitation of SMED:
Although there is huge benefit of SMED, but there are still some limitations of SMED.
The one major limitation about SMD is that it is important to understand the complete process where SMED has to be implement, we can’t skip even a single step of the process, otherwise moto of correct job change will not fulfil.
The second important limitation about SMED is that, we have to depend on the best skills of the company and the leaders, it is completely man dependent (at least at the initiation of the SMED).
Huge time required to train the people and make sure that everyone is trained about the new process of SMED and also know how will do which task how much time it will take to complete.
Now, we able to understand about SMED , advantages and disadvantages about it. Now to implement SMED in the company is all depend upon the company policies and on senior management. If management really think that SMED has to be implemented in the company then there should be complete study of the process and take care of all the advantage and disadvantage before implementing SMED and one more important thing which we have to keep in our mind that SMED process should not be costlier than the running production cost.
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