Quick Changeover and SMED

Superfactory Manufacturing Excellence Series

Lean Overview
5S & Visual Factory
Cellular Manufacturing
Jidoka
Kaizen
Poka Yoke & Mistake Proofing
Quick Changeover & SMED
Production Preparation Process (3P)
Pull Manufacturing & Just In Time
Standard Work
Theory of Constraints
Total Productive Maintenance
Training Within Industry (TWI)
Value Streams
Contents
• Introduction
• Background and History
• Components and Implementation
– Changeover and Changeover Time
– Traditional Setup
– SMED (Single Minute Exchange of Dies)
– SMED Process Steps
– Ideas for Improvement
• Knowledge Check

© 2007 Superfactory™. All Rights Reserved. 2

Introduction
• Quick Changeover is one of the core
concepts of lean manufacturing
• A rapid and efficient way of converting a
process from running the current product to
running the next product
• Also known as “single minute exchange of
dies” (SMED) – derived from the desire to
change over any process within minutes
• instead
Reducesofthe
hours
waste of inventory by creating
shorter production runs that better align with
customer demand

© 2007 Superfactory™. All Rights Reserved. 3

Background and History
• Developed in the late 1950’s and early
1960’s by Shigeo Shingo, chief engineer of
• Toyota
Land costs in Japan were very high,
therefore it was not feasible to store large
inventories of vehicles
• Quick Changeover provided a solution to the
economic lot size problem of traditional
manufacturing, which promoted large lot
sizes

© 2007 Superfactory™. All Rights Reserved. 4

Components and Implementation
• Changeover and Changeover Time
• Traditional Setup
• SMED (Single Minute Exchange of Dies)
• SMED Process Steps
• Ideas for Improvement

© 2007 Superfactory™. All Rights Reserved. 5

Real World Examples
• 3000-ton sheet metal stamping press
– Before: 4 hours
– After: 3 minutes
– Improvement: 98.7%, or a factor of 80
– Now the same press can make multiple parts
(hoods and doors in this case) for the Camry, only
what is needed for the next hour of production.
• 400-ton LIM molding press with 16-cavity
tool
– Before: 3 hours
– After: 18 minutes
– Increase in effective capacity equal to 5,184
additional parts

© 2007 Superfactory™. All Rights Reserved. 6

Benefits of Setup Reduction
• Better quality
– Very defined setup processes
• Lower cost
– Less scrap and inventory
• Better flexibility
– Rapidly change from product to product
• Better worker utilization
– Less time spent on setup or waiting for the run to
start lead time and more capacity
• Shorter
• Less process variability

© 2007 Superfactory™. All Rights Reserved. 7

6 “Traditional” Setup Steps
1. Preparation
– Ensures that all the tools are working properly and are in the
right location.
1. Extraction
– The removal of the tooling, raw material, and support equipment
after the production lot is completed.
1. Mounting
– The placement of the new tool, support equipment, and raw
material before the next production lot.
1. Establishing Control Settings
–Setting all the process control settings prior to the production
1. First Run Capability
run.
– This includes the necessary adjustments required after the first
trial pieces are produced.
1. Setup Improvement
– The time after processing during which the tooling,
machinery is cleaned, identified, and tested for functionality
prior to storage.

© 2007 Superfactory™. All Rights Reserved. 8

The SMED Process
• Step 1 – Observe and record.
• Step 2 – Separate internal and external
• activities.
Step 3 – Convert internal activities to
external activities.
• Step 4 – Streamline all activities.
• Step 5 – Document internal and external
procedures.

© 2007 Superfactory™. All Rights Reserved. 9

Step 1: Observe and Record
• Team-work
– Recorder
• Record overall duration (from last product to first good
product).
• Video recorders work very well
– • Describe the change (from what to what?).
Timers
• Time each step
– Fact collectors
• Breakdown the steps into actions – as much detail as
possible.
• Use a layman to ask uninformed questions – challenge
the “accepted norm”.

© 2007 Superfactory™. All Rights Reserved. 10

Combining equipment functionality
• Involves standardizing the equipment (parts,
tooling, processes) based on commonality between
setups to reduce the number of setup steps and
cycle times.
The common setup parts were identified and
replaced with this jig/holder combination.
By using these Notice how
fixtures, the different
parts are quantities of
automatically the same part
centered and can be setup
adjusted for with the same
height and fixture. Also,
flatness as a these setups
part of can occur while
External setup- the machine is
not Internal running.
setup.

© 2007 Superfactory™. All Rights Reserved. 11