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The Lean Enterprise
Set-up Reduction/ Quick Changeover
Lean Foundations
Continuous Improvement Training
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Introduction to Set-up Reduction /
Quick Changeover Concepts
based on a technique commonly called
‘SMED’ - Single Minute Exchange of Die
Objectives
•
Understand the concepts and principles of Setup Reduction.
•
Share some ideas and understand the benefits
of Set-up Reduction.
•
Apply the concepts, principles and techniques
of SMED to accomplish
Quick Changeovers !!
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Team Beliefs
 Safety comes first
 Quality and superior customer satisfaction is our
ultimate goal
 People are our most valued resource
 Blameless environment
 Continuous improvement is a way of life
 Teamwork (customer, supplier, associates)
 Integrity is never compromised
 We manage by facts (with data)
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What is SMED?
SMED stands for:
Single Minute Exchange of Die
?
Ideally, set-up time should be
anything less than 10 minutes …
Decreased set-up time;



reduces the need for inventory,
provides more flexibility and capacity,
enables us to better serve our customer!
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Benefits of Quick Changeover
Less adjustments means less chance for errors
Elimination of trial processing reduces material waste
Preparation of operating conditions in advance helps stabilize
product quality
Increases scheduling flexibility/capacity
Reduces need for on-hand inventory
Improved service levels for customers
Smaller runs means less likelihood of large scale defect
problems in inventory
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Set-up Time
Last
Good
Piece
First
Good
Piece
Total elapsed
Time
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Set-up Time
Shigeo Shingo (wrote the book on SMED…)
believed that:
any set-up time
can be reduced
by 59/60ths!
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Set-up Time
There are two types of setup time:
Internal Set-up:
Those activities that must be performed while the
machine is shut down. (Work content done in
addition to Machine Time.)
Example: Removing dies and tooling
External Set-up:
Those activities that are performed while the
machine is operating.
Example: Preparing tooling for the next set-up
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Set-up Reduction Process
1.
Observe and document the current set-up.
2.
Separate Internal and External elements.
3.
Improve each element.
4.
Observe and document the new set-up process.
5.
Standardize the new set-up procedure.
6.
Celebrate your success!!
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Observe and Document the Current Set Up
A. Select a specific set-up for improvement
B. Identify a set-up “kaizen” team.
C. Observe the set-up process:

Video Record the set-up process

Complete the Set-up Operations Analysis
chart (before Kaizen).
D. Prepare a Pareto chart for each time category.
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Record and Recommend
During this phase we:
Observe and document the existing set-up procedure
using
Time Observation and Video Recording techniques
- Analyze all work efforts
- Identify short-term solutions that can be
implemented with procedural changes, modifications to
existing fixtures and minor investment in tooling
Video Recording Tips
 Collect background data
 Select regular production “Parts”
 Determine equipment and operation
 Prepare/Evaluate site
 Where does operator stand?
 Where is the best position for the camera?
 Is there adequate lighting?
 Narrate
 Describe what is happening when the
operator blocks the camera or leaves
the area.
Analyze the
Time Observation & Video
 Review Time Observation and Video
with the team
 Identify opportunities
 Internal vs. External
 Value Added Vs Non-Value Added
 Normal vs. Abnormal
 Seven Types of Waste
 Automatic, Manual, Walking,
 and Waiting times
 Solicit ideas for countermeasures /
improvements
Observe and Document the Current Set Up
Set-up Operations Analysis Chart
Mach #
From
To
Area / Department
146
Model A
Model B
Machining Cell
Part #
Operation Time
Changeover Categories
Step No.
Changeover Element
Element
Elapsed
Internal
1
Pick-up tools from tool crib
(search)
19
19
19
2
Remove Fixture (Fixture
Change)
15
34
15
3
Look for Tools (Search)
5
39
5
4
Remove Fixture (Fixture
Change)
7
46
7
5
Clean & prepare subplate
(Fixture Change)
10
56
10
6
Prepare nex fixture (Fixture
Change)
20
1'16
20
7
Put on new fixture (Fixture
Change)
8
9
Before Kaizen Analysis
3456
Minutes
External
Waste
x
Improvement Plan
Mount hand tools on machine
x
x
Mount hand tools on machine
Standardize procedures to
externalize this step.
Establish common tooling for
all models.
Preset tooling (Tool Change)
6
1'48
6
Standardize procedures to
externalize this step.
11
2'14
12
Qualify 1st Piece (Gage)
12
2'26
12
2'26
2'26
2'11
Totals
x
Air wrench at machine .
Eliminate bolts - install
quick release. Design SMED
cart to load fixture.
4
15
x
x
1'42
Run 1st Piece (1st Piece)
x
Steel plugs for subplate.
4
11
Establish common tooling for
all models.
Standardize procedures to
externalize this step.
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x
x
x
x
x
x
x
15
15
Reduce
x
x
Remove preset tools (Tools
Change)
1'59
Internal to
External
See step 2.
22
11
Eliminate
Air wrench at machine .
Eliminate bolts - install
quick release. Design SMED
cart to load fixture.
1'38
Load new tooling (Tool
Change)
3/7/99
Goal of Improvement Plan
22
10
Date
x
Observe and Document the Current Set-up
Searching
- Looking for tools, jigs, fixtures, etc.
Fixture Change
- Replacing one fixture with another
Tool Change
- Replacing existing tooling
Programming
- Making adjustments or changes to a CNC program in order to
accommodate the new set-up
Walk time
- The time an operator must walk to retrieve a fixture, tools etc.
1st Piece
- The time required to produce a good unit after the initial set-up
Gage
- The time required to qualify the 1st piece
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Pareto Analysis on each Time Category
Set-up Pareto Analysis
80
70
time in min
60
50
40
30
20
10
0
Fixture Chg
Search
Tool Chg
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1st Piece check
Calibrate Gauge
Separate the Elements
Internal:
Those activities that must be performed while
the machine is shut down.
Example: Removing dies and tooling
External:
Those activities that are performed while the
machine is operating.
Example: Acquire fixture/tools for next set-up
Both types of actions must be separated. Once the machine is
stopped, the associate should never depart to perform any part of
the external set up.
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Separate the Elements
Set-up Operations Analysis Chart
Mach #
Minutes
14 6
Part #
Operation Time
Step No.
Changeover Element
Before Kaizen Analysis
3 456
From
To
Area / Department
Model A
Model B
Ma chining Cell
Changeover Categories
Element
Elapsed
Internal
19
19
19
External
Improvement Plan
1
2
Remove Fixt ure (Fixt ure
Cha nge)
15
34
15
3
Look for Tools (S ea rch)
5
39
5
4
Remove Fixt ure (Fixt ure
Cha nge)
7
46
7
5
Clea n & prepa re s ubpla t e
(Fixt ure Cha nge)
10
56
10
6
Prepa re nex fixt ure (Fixt ure
Cha nge)
20
1'16
20
7
Put on new fixt ure (Fixt ure
Cha nge)
22
1'3 8
22
8
Remove pres et t ools (Tools
Cha nge)
4
1'4 2
4
Es t a blis h common t ooling for a ll models .
x
3 /7/9 9
Goal of Improvement Plan
Waste
Pick-up t ools from t ool crib
(s ea rch)
Eliminate
Mount ha nd t ools on ma chine
Internal to
External
x
Mount ha nd t ools on ma chine
x
x
S ee s t ep 2.
S t eel plugs for s ubpla t e.
x
x
S t a nda rdize procedures t o ext erna lize
t his s t ep.
Air wrench a t ma chine . Elimina t e bolt s ins t a ll quick relea s e. Des ign S MED ca rt
t o loa d fixt ure.
9
Pres et t ooling (Tool Cha nge)
6
1'4 8
6
10
Loa d new t ooling (Tool Cha nge)
11
1'5 9
11
Es t a blis h common t ooling for a ll models .
11
Run 1s t Piece (1s t Piece)
15
2'14
12
Qua lify 1s t Piece (Ga ge)
12
2'26
12
2'26
2'26
2'11
x
15
Internal or External?
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x
x
x
x
x
x
x
x
15
S t a nda rdize procedures t o ext erna lize
t his s t ep.
Reduce
x
Air wrench a t ma chine . Elimina t e bolt s ins t a ll quick relea s e. Des ign S MED ca rt
t o loa d fixt ure.
S t a nda rdize procedures t o ext erna lize
t his s t ep.
Totals
Date
x
Develop Improvement Plan
5S +1 (6S) discipline is the key to quick changeover!
Every minute spent
looking for tools,
fixtures, drawings, dies,
jigs or other materials
adds to the set-up time.
A strong 5S foundation, with a ‘point-of-use’ (POU)
methodology, will ensure that all required materials
are in place when needed, are clean, and in working
condition.
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Develop Improvement Plan
Remember the ‘Wastes’ ?
(refer to the 7W’s)
 Defects
Punch Press
 Over-Production (inventory)
 Transportation
 Waiting
Tool Cart
 Inspection (mass)
 Motion
Storage area
for Dies
 Processing, itself
 + “Unused Creativity”
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Tool Room
Develop Improvement Plan
Specifically:
A. Convert as much of the internal set
up to the external set up.
B. Eliminate or reduce the internal and
external set up.
C. Eliminate the adjustment process.
Ultimate Goal: Eliminate Set-up!
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measure
separate
convert
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external
external
internal
internal
external
Steps: Reduce internal work gradually –
eliminate unecessary work
internal
reduce/eliminate (repeat)
Employ Improvement Initiatives
Once as much of the internal set-up has
been converted to external set-up and
waste has been eliminated:
– standardize the external set-up
actions
– utilize quick fasteners
– use supplementary tools – at the
‘point of use’ (POU)
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Employ Improvement Initiatives
Developing the Improvement Plan:
•
What must be done while the machine is
shut down?

What can be done while the machine is
running?

Challenge every element in the set-up !

Establish a sound 6S (5S+1) foundation.
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Improvement Checklist – an example
 Station tools, jigs, dies, etc. near the machine. (POU)
 Assure that all jigs, gauges, dies, tools, etc. function before
the set-up begins.
 Perform as many External elements as possible prior to the
set-up.
 Two people working together may reduce net set-up time
 Use functional clamps: One turn/ One motion
 Use visual control to eliminate adjustments.
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Application Best Practices
1) Make minor modification to the
existing fixtures.
2) Implement Point-of-Use (POU) techniques.
3) Identify additional tooling to remove attachment
from internal to external.
4) Adopt standardized tooling.
5) Document time savings.
Application Best Practices - Continued
For example:
 Slots in fixture and T-Bolts reduce
attachment time.
 A new part holder reduced the time required to
load and unload parts to fixture. Swing hook
eliminated the need to remove nut from bolt.
 Extra set slides allow detach to be completed on
external time.
Other ideas
1.
Quick Changeover begins and ends with the 5S’s.
2.
Change the Internal set-up into External, then improve
the remaining Internal set-up time.
3.
Bolts are our Enemies.
4.
If you have to use your hands make sure your feet stay
put.
5.
Don’t rely on Special Fine-tuning skills.
6.
Standards are standard: they are NOT flexible.
7.
Standardize all SMED Operations
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Ideas
The die heights of a punch press or molding machine can be
standardized by using the liner (spacer) so that stroke adjustment
will be unnecessary.
Source: Toyota Production System - Yasuhiro Minden
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Ideas
Examples of Quick
Fasteners
Usually a bolt is the most
popular fastening tool.
But because a bolt fastens
at the final turning of the
nut can loosen at the first
turn, a convenient
fastening tool that would
allow only a single turning
of the nut should be
devised.
Source: Toyota Production
System - Yasuhiro Minden
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Ideas
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Ideas
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Ideas
For example:
 A slide clamp reduced the time required to load and unload parts to fixture.
 2 hold-down clamps eliminated the need to tape parts during a glue-up operation.
 Set slide allows quick (temporary) alignment of 2 parts.
Document the New Set-up
A. List each element on the Set-up
Operations Standard Chart (after Kaizen)
B. Video tape the new set-up procedure.
C. Record the set-up time for each element
D. Note areas for future improvement.
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Standardize the New Procedure
Set-up Operations Standard
After Kaizen
Mach #
Minutes
From
To
Area / Department
Date
Part #
Operation Time
Step No.
Changeover Element
Element
Elapsed
Changeover Categories
Internal
External
Waste
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Comments / Future Improvement Plans
Standardize the New Procedure
The Set-up Operations Standard chart will
become the basis for the new set-up
procedure.
Prepare the appropriate detail and work
instructions that will be included on the Setup Operations Standard chart.
Assure that all appropriate personnel are
trained in the new procedure.
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The Lean Enterprise
Set-up Reduction/ Quick Changeover
Lean Foundations
Continuous Improvement Training
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