SMED Implementation, Step -5

SMED Implementation , Step - 5

Improve external changeover activities 

In my last blog, SMED Implementation, Step 4 ( i.e. improve internal changeover activities; Link : SMED Implementation, Step 4), I have elaborated different methods and techniques that can be utilized to simplify and streamline the internal setup activities, in order to have reduced changeover time. Similar approach may also be adopted to simplify the external activities (i.e. the activities that can be performed, while the process is still running). 

In Step 5 of SMED implementation, each and every external activities are evaluated in terms of following questions - 

1. How the activities can be simplified and can be completed in less time?

2. What kind of changes in process and sequence may bring results?

As detailed in my past blogs, i.e. in Step 3 and Step 4 of SMED implementation, here also we may need to do a cost vs. benefit analysis to prioritize the external work elements, upon which action can be taken sequentially (from high priority to gradually low priority). to simplify the external activities the techniques described in Step 4 of SMED Implementation ( Link : SMED Implementation, Step 4), are quite fruitful. Along with them, some other techniques are also useful as described below - 

     

a. Visual Factory :  Visual factory refers to an approach of lean manufacturing process, that emphasises on practicing visualization of information throughout the work place. . It is in line to with the common 5S practice which promotes the concept, that states that there should be place for everything and everything needs to be kept at it's designated place. Visual control, visual guidelines and visual standards displayed in the work area helps to improve performance by -
          (1) Reducing or eliminating searching time of materials or equipments and tools,
          (2) Enhances safety by providing safety warnings and precautionary information,
          (3) Enhances effectiveness of decision making through colour coded status display,
          (4) Boosts productivity by providing information to operators, where and when they need it.

Figure 1. Some examples of visual factory concepts 

b. Colour Coding : Colour coding is a method that brings ease in decision making. A typical example commonly used in packed food industry is that we observe RED  dot to designate Non Vegetarian Packed Food,  where as Green dot signifies Vegetarian Packed Food. Below are some examples of colour code practiced in industry. 

Figure 2. Some examples of common colour coding practiced in industry for ease of identification 

c. Practicing Standardised Setup : Standardised work practices such as organizing the required toolings and materials in proximity, Standardised loading and unloading process, Standardization of operation sequence, etc.  helps in having reduced time consumption in external work elements. 

Figure 3 below shows, an assembly line where the tools and parts are kept in proximity of the operator  to make him able to do faster operation. Materials are kept in the identified and designated location reduces searching time. 

Figure 3. Tools and parts kept in proximity and part kept in designated locations 

Figure 4 below shows unloading and reloading of fixture made easy by using standardized trolley. With this kind of trolley safety of operator is also taken care by the designer. 

 Figure 4. Use of standardise trolly for unloading and reloading of new fixture during changeover 

d. Using Check-sheets : Check-sheets are essential to provide guidance to the sequence of activity that needs to be performed during changeover. The external activities needs to be in standard chronology in order to avoid chaos.  Figure 5. is an example of pre-processing, during-processing and post-processing activity  check sheet.  These check sheets helps in ontime preparation of the work elements before, during and after setup. 

Figure 5. Check sheet for setup or changeover activities

e. Operator training on new processes : Once the internal and external activities are simplified and  streamlined, it is essential to revise the standard operating processes and giving adequate training to the operators for smooth running and sustainability of the new process. 

Deliverables of Step 5 of SMED Implementation i.e. "Improve external changeover activities" :

    (1) Updated set of work instructions and simplified process flow. 

   (2) Reduce execution time of external setup activities and there by observing a significantly reduced setup or change over time.   

In the next blog I will elaborate Step 6 of SMED Implementation i.e. "Mechanizing the setup or using automation" ( Link : Under preparation). If you find the blog is useful then share the link with relevant people. Give your comments and feedbacks in the comment section below. 

Happy Learning!