In the world of manufacturing, the ability to quickly switch between product variations or production runs is a major competitive advantage. One of the most effective techniques for reducing setup times and improving overall efficiency is SMED, which stands for Single-Minute Exchange of Dies. Originally developed by Shigeo Shingo, SMED is a lean manufacturing method designed to reduce the time it takes to change over equipment from one production run to another.
By minimizing downtime and speeding up changeover processes, SMED helps manufacturers enhance flexibility, increase productivity, and reduce costs. In this blog post, we’ll walk you through the key steps for implementing SMED in your operations.
What is SMED?
SMED is a methodology that focuses on reducing the setup time—the time it takes to change over machines or equipment between different production runs. The goal is to perform the changeover in under 10 minutes (hence “single-minute”). This is achieved by separating internal setup activities (those that require the machine to be stopped) from external setup activities (those that can be done while the machine is still running).
By implementing SMED, companies can achieve faster transitions, increase equipment utilization, and respond more effectively to customer demand.
Key Benefits of Implementing SMED
Before diving into the implementation process, let’s take a quick look at the benefits that SMED can bring to your operations:
- Reduced Downtime: SMED helps minimize the downtime between production runs, allowing for higher equipment utilization.
- Increased Flexibility: Faster changeovers mean you can switch between different products or product variations quickly, improving responsiveness to customer orders.
- Improved Productivity: By eliminating long setup times, your team can produce more products in less time, leading to greater throughput.
- Lower Costs: Reducing setup time reduces labor costs and helps lower the total cost of production.
- Better Inventory Management: Faster changeovers reduce the need for large batches, resulting in better inventory control and less waste.
Now that we understand the importance and benefits of SMED, let’s explore the step-by-step process for implementing it in your operations.
Step 1: Analyze Your Current Setup Process
Before you can improve your changeover process, you need to fully understand how it works right now. The first step in implementing SMED is to carefully analyze your current setup procedures. This involves:
- Documenting the Current Process: Record all steps involved in the changeover process, including internal and external activities. Internal activities are tasks that can only be performed when the machine is stopped, while external activities are tasks that can be completed while the machine is running.
- Measuring Setup Times: Track the amount of time spent on each activity in the setup process. This will help you identify where the longest delays occur.
- Identifying Bottlenecks: Look for bottlenecks or areas where excessive time is being wasted. These are the areas you should focus on improving during the SMED implementation.
Step 2: Separate Internal and External Setup Activities
The next step is to separate internal and external setup activities. This is a fundamental principle of SMED, as it allows for parallelization of tasks. By performing external activities while the machine is still running, you can reduce the total changeover time.
- Internal Setup Activities: These are tasks that must be done while the machine is stopped, such as adjusting the machine settings, changing dies, or installing new tooling.
- External Setup Activities: These are tasks that can be done while the machine is still running, such as gathering tools, preparing materials, or making adjustments to machine controls.
Look for opportunities to move internal tasks to external tasks or parallelize tasks where possible. For example, if an operator is waiting for a tool to be ready before performing an internal task, this waiting time can be eliminated by preparing the tool in advance (during the machine’s operation).
Step 3: Streamline Internal Setup Activities
Once you’ve identified which tasks are internal, focus on streamlining them to make them as quick and efficient as possible. The goal here is to reduce the time spent on each internal activity so that the machine can be brought back online faster.
Here are some strategies to streamline internal setup:
- Standardize Work Procedures: Create standardized work procedures for each internal setup task. Ensure that everyone follows the same process to minimize errors and inefficiencies.
- Reduce Tool Changeover Time: Invest in quick-change tooling, such as clamp systems or modular components, that allow for faster and easier tool swaps.
- Organize Tools and Equipment: Ensure that all tools and equipment are readily available and organized in a designated area so that operators don’t waste time searching for what they need.
- Pre-set Tools and Equipment: If possible, prepare tools and materials for the next production run while the machine is still running, so they are ready for the changeover process.
Step 4: Streamline External Setup Activities
For external setup tasks, your goal is to perform them as efficiently as possible without interrupting machine operations. External setup activities can often be done simultaneously, so find ways to overlap tasks to save time.
Here are a few tips for streamlining external setup:
- Prepare Materials in Advance: Set up materials, dies, or components while the machine is still running. This eliminates the need to wait until the machine is stopped to begin preparations.
- Create Pre-Set Kits: Assemble kits containing all necessary tools, materials, and components for the next production run. This reduces the time spent gathering items during the changeover.
- Improve Communication: Ensure that operators and support staff (e.g., maintenance personnel or materials handlers) are well-coordinated so that the setup activities can be performed smoothly and without delays.
Step 5: Implement Quick-Change Tools and Fixtures
One of the most effective ways to reduce setup time is to implement quick-change tools and fixtures. These allow operators to change tools or dies with minimal effort and time, reducing the overall internal setup duration.
Some examples of quick-change solutions include:
- Quick-Change Tooling Systems: Tools or dies that can be easily swapped with minimal adjustments or downtime.
- Modular Tooling: Tooling that can be easily configured for different product types without requiring a full tool change.
- Clamp Systems: Quick-release or hydraulic clamping systems that eliminate the need for manual adjustments or fasteners.
Investing in quick-change tools can significantly reduce the time spent on internal setup and improve overall changeover efficiency.
Step 6: Continuously Monitor and Improve
Implementing SMED is not a one-time process; it requires ongoing monitoring and continuous improvement. Once the initial changes are made, track the impact on setup times, production efficiency, and overall productivity. If necessary, refine your processes by applying the following principles:
- Kaizen (Continuous Improvement): Encourage a culture of continuous improvement where employees suggest and implement ideas for reducing setup time.
- Standardize and Document Best Practices: Once improvements are made, standardize and document the new processes so that all team members follow the same procedures.
- Analyze Data: Regularly analyze data on setup times to identify further areas for improvement and track progress over time.
Step 7: Foster a SMED Culture
For SMED to be successful, it’s important to foster a culture of change within your organization. This means getting buy-in from all levels of the workforce, from management to operators. Provide training and involve all employees in the process, ensuring they understand the importance of fast changeovers and are empowered to suggest improvements.
