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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