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Extended model for SMED application through detriment to the quality of the product (Joshi and Naik,
assessment of supporting tools 2012).
Matteo Mario Savino, Antonio Mazza, Vincenzo Della Set-up and adjustment is one of the six big losses of
Selva TPM, and SMED is the heart of just-in-time
production (Schmidt, 1997), TPM and continuous
Department of Engineering, University of Sannio, improvement process (Goubergen and Landeghem,
Piazzza Roma, 21 82100 Benevento, Italy 2001). A set-up can be defined as the elapsed time
between the last product leaving the machine and the
1 Abstract first good product coming out. Berna (2011) identified
three main reasons for setup reduction, i.e. flexibility,
The present work aims to front the problem of Single improvement of available capacities of the line and cost
Minute Exchange of a Die (SMED) for changeover. reduction.
After a literature review of SMED techniques an
extension of the traditional SMED is proposed. In this The quality of a set-up is determined by three key
extensions we include additional steps have to better elements: technical aspects of equipment and tools, the
characterize the whole process of SMED application. To organization of the work (who does what when) and the
each step, some tools are proposed and assessed with method used (how). All three key elements have to be
respect to their contribution for a fair analysis. The optimized (Van Goubergen, 2010). There are several
model is developed within an Action Research in a publications and case studies available on how set-up
production line for automotive components. Results of times can be reduced in existing situations. Basically, all
the on-field application are shown in terms of set-up the approaches are derived from the SMED method,
times reduction and activities rationalization. originally developed by the Japanese Industrial Engineer
Shigeo Shingo for reducing the time to exchange dies. An
in depth overview and application case is provided by
Moreira and Silva Pais (2011). This method gives a
2 Introduction straightforward approach to improve existing set-ups and
to easily obtain a reduction of up to 90%, with mostly a
Organizations main problem is how to cut costs, while
producing small numbers of many types of products with moderate investment (Van Goubergen and Van
Landeghem, 2002). The implementation of SMED starts
seasonal variation. The solution of this problem is built
with a preliminary stage consisting in a previous analysis
up with lean based production systems (zkavukcu and
in order to clearly understand the changeover process,
Durmuolu, 2010). There are many tools of lean
production, as value stream mapping, cellular identifying all the setup operations involved (Sousa et al.,
2009). SMED or quick changeover allows manufacturers
manufacturing, 5S, SMED, pull production systems and
to keep less inventory while supporting customer
production smoothing. The rewards of rapid, high-quality
demand for products. SMED or quick changeover
changeovers are widely described and they are advocated
as a key instrument to enhance competitiveness, assisting programs have many benefits for manufacturers e.g.
reducing downtime associated with the changeover
both responsiveness to external market demands and
process to reducing the waste created during startup
internal control of factory operation (McIntosh et al.,
(Tharisheneprem, 2008). Dave and Sohani (2012)
2007).
provided also an extended literature review on SMED.
The work collects and organizes a selection of feasible
tools applicable for a SMED analysis. It is based on an Despite the theoretical approach of Shingo (1985),
SMED was composed of three stages (i.e. Separate
extension of the traditional SMED model provided by
Internal and External setup, Shift Internal setup to
Fritsche (2011) where additional steps have been
External Setup and Improve all elemental operations)
included to fully characterize the whole process of
SMED application. The model is aimed to be a guideline which serve as the guide/process on reducing the setup
time of a particular equipment. Fritsche (2011) proposed
following the implementation steps for changeover
a SMED-based approach iterating over the basic
optimization. To each step, some suitable tools for a
principles avoidance, reduction and shifting of waste and
deep and critical analysis are proposed and assessed with
respect to their contribution for a fair analysis. The efforts (Figure 1).
model has been tested in a real scenario represented by a
production line for automotive components where a
changeover optimization through SMED techniques was
necessary. Results of the on-field application are shown.
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for the application of a SMED analysis in a test case for Figure 3, our model integrates and includes the one of
an on-field validation. Fritsche (2011) (steps in white color) (Figure 3a)
extending it (steps in orange color) and assigning
An overview of the research methodology is shown in supporting tools (with labels) (Figure 3b).
Errore. L'origine riferimento non stata
trovata.2. Step 1:
Recording and
Step 2:
Separation
Step 3:
Convertion
Step 4 and 5:
Optimization of
Step 6:
Parallelization of
analysis Int./Ext. Int./Ext. Int./Ext. Operations
Step 0:
Training on SMED
Extended model Applicable tools principles
for SMED application for SMED
Step 3.1:
Figure 2. Research methodology
TIME MEASUREMENT Evaluate
ERGONOMICS qualitative
More in details, the extended model considers previous improvements
on-field studies on SMED analysis performed by action
research methodology and existing scientific works
Positive NO
extracted from a literature analysis. According to A2, the Results?
model arranges and deepens SMED steps focusing on
YES
possible scenarios (if-else case) which can originate from
the process. A selection of feasible and applicable tools Step 4 and 5: Step 6: Step 7:
to SMED technique have been conducted as a result of Optimization of Parallelization of Assignment of
A3; this has been done through the analysis of tools Int./Ext. Operations Operations
adopted in several firm areas. Such tools have been POKA YOKE FISHBONE DIAGRAM TIME MEASUREMENT
integrated into the extended model to complete its KAIZEN BRAINSTORMING SPAGHETTI DIAGRAM
representation. SPAGHETTI DIAGRAM ERGONOMICS
The model is aimed to describe with more details the Figure 1b - Extended model for SMED
steps composing a SMED procedure associating main
important tools whereas possible. We selected the
following set of applicable and supporting tools: More in details:
brainstorming, 5S, kaizen, visual management, fishbone
diagram, spaghetti diagram, time measurement, Step 0. Before starting with the application of SMED
ergonomics and poka yoke. It is worth mentioning that procedure, managers and employees must
the application of SMED techniqueis possible if understand the benefits of such technique
changeover is almost standardized even if operations are through the awareness of its main steps and
not optimized or correctly performed. Vice versa it has objectives. The aim is changeover time
no sense to deal with separation, optimization and reduction but above all the creation of a
parallelization of internal/external activities. As shown in comfortable working environment free from
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risks and safety oriented. People involvement is activities flow that has been documented and
fundamental for a proper and shared adoption decided in accordance to a deepened and
and application of SMED technique and in this criticality analysis.
sense continuous training is an operative means.
Step 1. Changeover activities are analyzed through It is worth mentioning that SMED technique is a
direct observation and video recording. The aim continuous process which is not applied just once. A
is to analyze the as-is state of the changeover continuous updating of changeover procedures and
which is the basis for proposing improvements activities is required in accordance to new criticalities,
or validate current procedures. This can be done internal employees suggestions or modification of the
through supporting tools of (i) spaghetti external environment (e.g. safety law disposals, new
diagram, ergonomics and time measurement for technologies).
a fair analysis and (ii) a fishbone diagram for
detecting errors and validate procedures. 6 The industrial test case
Step 2. Separation of IED and OED is the pillar of
SMED. To properly separate such activities, The extended model has been applied to a real scenario
brainstorming with employees, and fishbone represented by an assembly line (Figure 4) producing two
diagram can assist the analysis. different items, i.e. water pump (Lot A) and oil pump
Step 3. IEDs are converted into OEDs (whereas (Lot B) for two different automotive engines.
possible) by taking into account mainly 5S
principles with reference to workplace
organization and cleaning requirements.
Brainstorming activities are necessary for
sharing ideas and suggestions.
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Tipo di Variazio
Cost
Intervento migliorame ne
o
nto tempo
Introdurre
una chiave a
Facilit,
stacco per
1 protezione 50 ---
serraggio
tools
fermi presse
e leak test
Migliorare la
posizione dei
2 pannelli dei Facilit --- ---
robot (a
centro linea)
Table 2. Extract of the tasks Far passare
in alto tutti i
3 Sicurezza --- ---
Convert Int./Ext. changeover activities cavi intorno
alla stazione
The current changeover process has been carefully Sostituire i
examined with the goal of converting the more internal moschettoni
activities into external. The analysis highlighted that the a vite con
actual list of external tasks could be reduced by 4 Facilit 20 ---
quelli a
intervening through simple actions. As an example, the chiusura
main measure to accomplish this task has been identified rapida
with anticipating withdrawal and shifting (op #3 and 4) Facilit,
of components related to the next lot from supermarket Migliorare le Sicurezza,
to production line. Material supplying can be conducted
5 maniglie del protezione ---
Vice versa some operations are intrinsically internal, e.g. 100
leak test tools,
pliers and press substitution (op #8) and it is not possible Ergonomico
any anticipation while producing the previous lot of Portare i
products. tools di Spazio,
6 pressa 1 e protezione ---
Evaluate improvements 500
pressa 2 nella tools
linea
The great amount of internal activities suggested
important achievements for changeover reduction. In our Riorganizzar
application case, evaluation of improvements was very e il carrello
fair due to the identification of several activities which principale
could be shifted from internal to external with an per Protezione
important time saving. This implied the possibility to 7 contenere le tools, -1,5 min
700
forecast a reduction of overall changeover time and pinze dei facilit
clearly indicated to proceed with the further steps of robot ed i
SMED. In other cases, i.e. if changeover activities are tools per
already well optimized, it could be necessary to use more lattrezzaggio
precise measure to define time improvements. It is worth Creare un
mentioning that changeover improvement must be carrellino
measured not only with respect to time reduction but ausiliario con
also with respect to ergonomics improvements which can un sostegno
be necessary to optimize tasks contributing to a safer and per le pinze Protezione
8 ---
comfortable working environment. dei robot ed tools 200
una
Optimization of Int./Ext. changeover activities posizione
vuota di
A critical analysis of current tasks has been conducted for appoggio
the optimization of existing procedures related to internal Introdurre
and external operations. In table 3, reporting cost, time dei colori
saving and typology of improvement has been defined to identificativi
characterize each proposed optimization of tasks. per pinze e
9 Facilit 50 ---
tools presso
il carrello
principale e
le stazioni
10 Settare i Facilit, ??? -3 min
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XIX Summer School "Francesco Turco" - Industrial Mechanical Plants
45% for operator A and B respectively as shown in Table 1. Agustin R.O., Santiago F., (1996), Single-minute
5. exchange of die, Advanced Semiconductor
Manufacturing Conference and Workshop, 214-217
Covered Meters [m] 2. Alves A.S., Tenera S., (2009), Improving SMED in
OP Saving
Before Actual the Automotive Industry: A case study, Production
A 89,8 64,1 28% and Operations Management Society 20th Annual
B 88,3 48,3 45% conference Orlando, Florida U.S.
Table 5. Covered meters 3. Basu R., (2008), Chapter 7 - Tools for
improvement, Implementing Six Sigma and Lean,
112-132
4. Berna U., (2011), An Application of SMED
Methodology, World Academy of Science,
Engineering and Technology, 100-103
5. Dave Y., Sohani N., (2012), Single Minute
Exchange of Dies: Literature Review, International
Journal of Lean Thinking, 3, (2), 27-37
6. Fritsche R., (2011), Reducing set-up times for
improved flexibility in high-mix low-volume electric
drives production, 1st International Electric Drives
Production Conference (EDPC), 74-77
Figure 8: Spaghetti diagram Before/actual situation 7. Goubergen D.V., Landeghem H., (2001), An
Integrated Methodology for More Effective Set Up
An additional interesting result is also observed on Reduction, IIIE Solutions 2001 Conference
changeover duration and its time variability. Figure 9 8. Joshi R.R., Naik G.R., (2012), Application of
shows in blue changeover duration before the application SMED Methodology- A Case Study in Small Scale
of SMED and in red changeover duration after the Industry, International Journal of Scientific and
application of SMED. As we can see referring to the red Research Publications, 2, (8), 1-4
bars, after the initial variability due to on field training 9. McIntosh R., Owen G., Culley S., Mileham T.,
period performed in collaboration with managers, (2007), Changeover Improvement: Reinterpreting
duration tends to settle on average values of 50 minutes, Shingos SMED Methodology, IEEE
in line with forecast of our time analysis. Above all, we Transactions on engineering management, 54, (1),
observed a strong reduction of time variability i.e. the 98-111
duration is almost ever on the average of times, as shown 10. Moreira A.C., Silva Pais G.C., (2011), Single Minute
in Table 6. Exchange of Die - A Case Study Implementation,
Journal of Technology Management & Innovation,
6, (1)
11. zkavukcu A., Durmuolu M.B., (2010),
Production Smoothing Decisions with Seasonal
Variation through Value Stream, 40th International
Conference on Computers and Industrial
Engineering (CIE), 1-6
12. Schmidt S., (1997), Total productive maintenance
and change over reduction engineering a way to
increase quality and productivity, Portland
International Conference on Management and
Technology Innovation in Technology
Management - The Key to Global Leadership
Figure 9. Changeover duration before / after the 13. Sekine K., Arai K., (1992), Kaizen for quick
application of SMED changeover: going beyond SMED, Productivity
Press
Average duration Sav Standard deviation Sav 14. Shingo S., (1985), A Revolution in Manufacturing:
Before Actual ing Before Actual ing The SMED System, Cambridge, MA: Productivity
15. Sivasankar M., Dhandapani N., Manojkumar S.,
01h:54m 00hh:43m 62 01hh:19 00hh:04 94 Karthick N., Raja K., Yuvaraj J., (2011),
m:06ss m:44ss % mm:36ss mm:22ss % Experimental verification of Single Minute
Table 6: Changeover representative times Exchange of Dies (SMED), Recent Research in
Science and Technology, 3, (3), 92-97
7. Conclusions 16. Sousa R.M., Lima R.M., Carvalho J.D., Alves A.C.,
(2009), An industrial application of resource
References constrained scheduling for quick changeover, IEEE
International Conference on Industrial Engineering
and Engineering Management, 189-193
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