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...