SMED Implementation - "Step 1"

SMED Implementation - "Step 1"

In continuation to my last Blog (Link : Implementing SMED)...

In Single Minute Exchange of Die implementation process the Step 1 is " Document the setup/ changeover and separate events in to internal and external". In this step the project execution team works together to identify all the work elements of setup / changeover. The most effective way of doing this is to video graph the entire setup/ changeover. Minimum 5 setups needs to be documented in this process. A setup/ changeover recording sheet  may be prepared to capture the observation, which will act as ingredient to brainstorming process. the most important items that needs to be documented in a setup/ changeover recording sheet are -

1. Description of each work element
2. Time taken by the work element from start to end

The setup/ changeover recording sheet  will also help to identify the internal and external work elements. For everyone's reference, description of Internal and External work element is once again  given below :  

• Internal Work Element :- Activities or work element that can only be performed when the equipment or machine is completely stopped. 
• External Work Element :- Activities or work element that can be performed when the equipment / machine is in operation.

A typical example of "Setup / changeover recording sheet" is given below :

In this worksheet, wasted time or wasted time slot, which may be an outcome of  an abnormal situation. The wasted time can be further categorized as follows : 

#	Wasted Activities	Explanation
1	Setup waste - External Element	Activities such as searching, finding and transportation of tools , jigs, fixtures nuts bolts and other items and delays due to instruction error or miss communication.
2	Setup Waste - Internal Element	Activities related to machine alignment or tool alignment, zero positioning etc. during machine / equipment setup.
3	Replacement Waste	Activities such as cleaning of machine during replacement, sharpening of tools, hammering during tool replacement, low speed de-clamping and clamping of job or tool etc.
4	Adjustment Waste	Activities that requires, machine cycle to dry run for observation without producing a single part such as alignment, zero positioning indexing, die aligning, pressure adjustment, stroke and stop adjustment

Some useful tips to keep note of are detailed below :

1. Covering all work elements :  A typical setup/ change over may have 30 to 50 work elements. All the work elements must be thoroughly covered.
2. Clear separation of Internal and External Elements :  All the work elements identified during study must be clearly segregated In to external work element.
3. Human related work elements :  Work elements conducted by operators must be studied deeply. Always there remains a scope of optimization in work elements related to human.
4. Variation in Analysis :  To reduce the variation of observation within team members, video analysis must be done. Commonization and normalization  in terms of observation recording, must happen within the team to have better clarity.
5. Care during observation : Two things must be taken care as  :                       

• The observation video recording of setup/ change over must be uninterrupted.
• The observer or the observing team must let the changeover happen in its normal course without interfering.

Deliverables of Step 1 of SMED Implementation :

1. Completed list of Work elements related to Setup/ Changeover.
2. Time taken by each element while performing.
3. Identification of waste full activities wasteful work elements.
4. Separated internal and external category of work elements.

The Step 2 of SMED Implementation i.e. "Standardize external setup activities" is detailed in my next blog ( Link : SMED Implementation Step 2). 

Wish You a Happy Learning !