What is Single minute Exchange of Die (SMED)?
Quick Definition
SMED is the term used to represent the Single Minute Exchange of Die or setup time that can be counted in a single digit of minutes. SMED is often used interchangeably with “quick changeover”. SMED and quick changeover are the practice of reducing the time it takes to change a line or machine from running one product to the next. The need for SMED and quick changeover programs is more popular now than ever due to increased demand for product variability, reduced product life cycles and the need to significantly reduce inventories.
Expanded Definition
The successful implementation of SMED and quick changeover is the key to a competitive advantage for any manufacturer that produces, prepares, processes or packages a variety of products on a single machine, line or cell. SMED and quick changeover allows manufacturers to keep less inventory while supporting customer demand for products with even slight variations. It also allows manufacturers to keep expensive equipment running because it can produce a variety of products. SMED has a lot of hidden benefits that range from reducing WIP to faster ROI of capital equipment through better utilization.
To understand how SMED can help we have to look at the changeover process. Typically when the last product of a run has been made the equipment is shut down and locked out, the line is cleaned, tooling is removed or adjusted, new tooling may be installed to accommodate the next scheduled product. Adjustments are made, critical values are met (die temperature, accumulators filled, hoppers loaded, etc.) and eventually the startup process begins – running product while performing adjustments and bringing the quality and speed up to standard. This process takes time, time that can be reduced through SMED.
Effective SMED programs identify and separate the changeover process into key operations – External Setup involves operations that can be done while the machine is running and before the changeover process begins, Internal Setup are those that must take place when the equipment is stopped. Aside from that, there may also be non-essential operations. The following is a brief example of how to attack the SMED process:
• Eliminate non-essential operations – Adjust only one side of guard rails
instead of both, replace only necessary parts and make all others as universal as possible.
• Perform External Set-up – Gather parts and tools, pre-heat dies, have the correct new
product material at the line – there's nothing worse than completing a changeover only to find that
a key product component is missing.
• Simplify Internal Set-up – Use pins, cams, and jigs to reduce adjustments, replace nuts
and bolts with hand knobs, levers and toggle clamps – remember that no matter how long the screw or
bolt only the last turn tightens it.
• Measure, measure, measure – The only way to know if changeover time and startup waste
is reduced is to measure it!
Always measure time lost to changeover and any waste created in the startup process so that you can benchmark improvement programs. Ever see a racing pit crew? They have mastered SMED and quick changeover! In less than 15 seconds they can perform literally dozens of operations from changing all tires and refueling the car to making suspension adjustments and watering the driver. Watch closely next time – you will always see one person with a stopwatch benchmarking their progress.
How Can SMED Help My Organization?
SMED and quick changeover programs have many benefits for manufacturers. From reducing downtime associated with the changeover process to reducing the waste created during startup. Additional benefits include:
• WIP and lot size reduction
• Finished goods inventory reduction
• Improved equipment utilization/yield
• Increased profitability without new capital equipment purchase
Eye-opening gains are often discovered when a well-designed SMED or changeover program is implemented. Can your company benefit from a changeover reduction program?
Vorne Products and SMED
A manufacturing truth – “you cannot change that which you do not measure”. Vorne visual displays provide real-time information to enhance productivity and create a true visual factory environment – from the shop floor to the top floor.
We offer many visual display and production monitoring products to serve a variety of plant floor applications. The following product solutions are some of the most common.
| Changeover in Process Timer | |
|---|---|
PROBLEM |
Everyone needs to know if a line is down for changeover or for other reasons. |
STRATEGY |
Exposing changeover time process engages the changeover team. Real-time display of changeover time also creates a sense of urgency that is not felt in a downtime report a day or week later. Display the changeover time goal in green and overage in red. Or show up to three phases of the changeover process each in its own color (green, red and amber). |
SOLUTION |
87/705 Programmable Timer – HH:MM:SS, HH:MM or MM:SS display of changeover time. Add dynamic tri-color digits for preset-based color change. Other formats include tenths of minutes or hours for maintenance teams that log time in this format. |
| Waste Count | |
PROBLEM |
Significant waste is created while we are smoothing out the line operation after a changeover. |
STRATEGY |
Show a real-time count of waste product. Exposing waste helps all involved work toward reducing waste created during the startup phase of a changeover. |
SOLUTION |
87/256 Event Counter – Show total number of reject pieces produced. Add dynamic tri-color digits to show previous lowest waste count in green and red when this value is exceeded. |
| Event/Accumulated/Average Changeover Timer | |
PROBLEM |
We perform several changeovers throughout a shift and lose track of our progress. |
STRATEGY |
Record and display last event and total accumulated changeover time. Additionally the total number of events and an average changeover time can be displayed. |
SOLUTION |
XL400 Large Digital, XL600 Multi-line and XL800 Alphanumeric production monitors can show last event and total accumulated changeover time as well as the number of events and the average changeover time to really fuel SMED and quick changeover programs. |
Call us toll free at 1-888-DISPLAYS (1-888-347-7529). We have a lot of practical experience with SMED and quick changeover programs and are happy to help – just call!
