SMED Implementation - Step 2

SMED Implementation - Step 2:

"Standardise external setup activities"

In SMED Step 1 (i.e. "Document the setup/ changeover and separate events in to internal and external"as detailed in link: SMED Implementation - Step 1) we have seen how the activities are categorized into external and internal work element. Now, in SMED Implementation Step 2 i.e. "Standardise external setup activities" the project execution team critically verifies the list of internal and external activities, and puts up a critical question to each of the work element, which is as follows : 

      - "Can this work element, as currently performed or with minimal change, be completed while the equipment is still running?"This exercise is done to reaffirm the list of external work elements. If the answer to the above question is "Yes" than the work element is definitely an external work element. 

      - Once the external work elements are identified move the work element in to before stage or after stage of the internal work element in the work sequence as appropriate. These work element sequencing is always to be done by the process owner or process expert.

      - Once the external work elements are identified they are made parallel to the mainstream setup/ changeover process. Thus the overall time of setup or changeover reduces drastically. An example is shown in the below figure 1: 

During video analysis of  any setup/ changeover process it is also needed to be seen that with a little or some small changes whether some internal activity can be converted in to external work element to further reduce the setup/ changeover time. In the figure 1 (above ) an example is shown, which states that preheating of dies and molds are done before putting them in to machine /equipment so that the operators don't need to wait for the machine or equipment to heat it during the process itself. 

In the FORMULA-ONE  race, tires are heated to the driving temperature before replacing during the race, so that the driver does not have to wait for his car to get to the required temperature. This is a very good example of SMED implementation to reduce changeover time. 

In most of the video analysis it has been observed that, the significant part of the setup / changeover time is wasted or lost due to searching for setup hardware and unavailability of stup informations. Some examples of setup hardware s are :  Tools, fixtures, nuts & bolts, clamping devices, measuring devices etc and Some examples of setup information s are : data sheets mentioning tools and machine setting and specific work instructions and special approvals.

So, Making tooling shadow boards and keeping the tools according to the type of setup and displaying data sheets at respective work stations and training is always helpful. Small workplace related kaizens are always helpful to have reduced setup time. Keeping additional clean set of common tools that otherwise have to be cleaned and reused during the setup activity may also be a helpful technique. Figure 3 shows some commonly used shadow boards.

Kaizens may be done on the following : 

             1. Organizing work stations

             2. Setup check sheets 

             3. Battle plans 

             4. Reduction of  human travel time and tooling transportation time (simplification  through                     Spaghetti Chart)

             5. Functional check point through refined check points 

After improvements are done, the external work elements are converted into parallel activities. Here a set of new and refined setup/ changeover standards are required to be made. An example of such a check sheet is shown below : 

 Deliverables of Step 2 i.e. "Standardize external setup activities" are as below : 

     1. A complete changeover standard is prepared considering all critical points like tool retrieval,               inspection, cleaning and quality checks.

     2. A list of work elements categorized into three categories: 

                                1. External work element

                                2. Internal work element 

                                3. Internal workelements that can be converted to external element with little or small change 

    3. List of possible Kaizens .

In my next blog I have elaborated on the step 3 of SMED Implementation (Link :SMED Implementation Step - 3) .