SMED Implementation, Step-7

SMED Implementation, Step-7

"Eliminate Changeover "

The last step of SMED implementation, i.e. Step 7 of SMED implementation is the step that talks about elimination of changeover time loss by completely eliminating the requirement of changeover. In my last blog, i.e. SMED implementation, Step 6 ( Link :SMED Implementation, Step-6) , i.e. mechanising or automating all setup activities, we have seen some examples of automated changeover to have reduced setup time.But by any means, if we are able to eliminate the need of changeover, then there will be no wastage of time at all in the name of changeover. 

This is achievable through evaluating and re-evaluating the product and process design multiple times. Some of the ideas are discussed below - 

(1) Part commonization is one of the major steps, that eliminates the need of changeover.In the product design itself, this option may be tried out, and once commonization is done,same sequence of operations will be applicable throughout.

(2) having dedicated machines for each individual component, is sometimes a cheaper option. This options must be evaluated in terms of cost vs. benefit analysis.
(3) Modification of toolings to produce multiple parts in a single go, may prove to be a great option in some cases.
e.g. - Instead of having several injection moulding tools to produce to produce different components, we can consider to have single injection moulding tool producing several components like an Air-fix model of  an air craft kit. The photograph of an air fx model and its assembling process has been shown in the below photograph.

Figure 1: Airfix model aircraft kit

The complete model kit can be produced in by a single injection moulding tool in a single go. Like step-6 of SMED implementation (i.e. Mechanizing or automation), Step-7 of SMED implementation (i.e. eliminating the changeover process) can be expensive and often time consuming. hence cost vs. benefit analysis is must.

SMED is one of the tools form the lean tool kit, which helps in methodically reduce setup/ changeover time. It incorporates just in time, waste reduction in process and 5S concept implementation, involves spaghetti analysis and most importantly the concepts of KAIZEN and team work. 

The more advanced version to this SMED concept which is now a days getting popular is OTED, i.e. Öne- Touch Exchange of Dies". 

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SMED Implementation, Step-6

SMED Implementation, Step-6

"Mechanizing the set-up or using automation for change over"

In my previous blogs, Step-4 of SMED Implementation (Link : SMED Implementation, Step-4) and Step-5 of SMED Implementation (Link: SMED Implementation, Step-5) I have detailed about the techniques of simplifying and streamlining internal and external work elements involved in the changeover process, and thus reducing the time taken in completing the whole process of changeover.

Here we shall talk about using automation or mechanizing some of the crucial or time taking and effort consuming activities, to have efficient and effective and less time consuming setup / change over. 

Like previous steps, here also before establishing or going for any form of automation, the changeover process we must do a cost vs. benefit analysis. In one of my previous blog SMED Implementation, Step-3 ( Link : SMED Implementation, Step-3) , cost vs. benefit analysis has been detailed. You can use it for reference. If the cost benefits does not justify usage of automation, we must revisit the previous steps of SMED that has already been done and we must try to see if we can try some more improvements, in the external and internal work element. 

To have brief overview to understand the word, automation, you can follow the wikipedia link - https://en.wikipedia.org/wiki/automation. 

Some examples of automations are given below: 

1) Automatic change of program in a robotic welding line (mostly practiced in automobile manufacturing factories ) of weld shop with the help of timer and sensors, to avoid line stoppage during model change (Automobile body change as per sequence).  Figure below shows the example of robotic welding and robotic sealant application process in a automobile industry.

Figure 1. Robotic welding process and sealant application process

2) Automatic paint selection process ina robotic welding line during colour change in the paint booths to have zero time loss. 

3) Programmed and automated soft drink selection process in the bottling plants of soft drinks which offers multiple soft drink options that gets bottle-filled in the same line in a sequence.

4) Automatic tool selection program for machining operation to guide operation wise indexing process supported by automated adjustments. 

One of the most important reasons of automated system implementation is to ensure safety of employee while handling heavy equipments and machine parts or tools may be hanging or suspender and while handling hazardous / corrosive items.

Deliverables of Step 6 of SMED implementation i.e. "Implementing partial or complete automation" are - 

1. Ensuring employee safety while handling heavy equipments and hazardous materials.

2. Bringing down change over time to much lesser level.

3. Human effort reduction or elimination.

4. Eliminating the chances of human error during setup or changeover.

In the next blog, (Link: Step 7 of SMED Implementation), I will give a brief on Step 7 of SMED Implementation, i.e. eliminating the changeover. 

To be continued...