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TMSSonline Total Manufacturing Systems Solutions
The Complete Lean Shop
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What is it: SMED (Quick Changeover) stands for Single Minute Exchange of Die. The SMED system is theory and set of techniques that make it possible to perform equipment set up and changeover operations in under 10 minutes – in others words, in the single minute range. SMED was originally developed to improve die press and machine tool set-ups, but its principles apply to changeovers in all types of process. SMEDs is one of the maun lean production methods for reducing waste in a manufacturing process, by providing a rapid and efficient way of converting a manufacturing process from running the current product to running the next product. This rapid changeover is key to reducing production lot sizes and thereby improving flow (Mura) which is a 'Lean' aim.

Why use it: To minimize machine downtime due to set-up changeover. The advantages of a quick changeover are:

  • Allows smaller economic lot sizes
  • Ability to produce a greater variety of parts
  • Reduces in process inventory
  • Reduces lead times
  • Minimizes machine downtime

Where to use it: For equipment that requires quick turn around times in a lean manufacturing enviroment.

When to use it: SMED changes the assumption that set ups can be done quickly, they can be done as often as needed. This means companies can make products in smaller lots, which has many advantages:

  • Flexibility: companies can meet changing customer needs without the expense excess inventory.
  • Quicker delivery: small lot production means fewer customers waiting time.
  • Better Quality: less inventory storage means fewer storage related defects. SMED also lowers defects by reducing Set up errors and eliminating trial runs of the new products.
  • Higher productivity: Shorter changeovers reduce down time, which means a higher equipment productivity rate.

How to use it: Shigeo Shingo recognises eight techniques that should be considered in implementing SMED.

  1. Separate internal from external setup operations
  2. Convert internal to external setup
  3. Standardise function, not shape
  4. Use functional clamps or eliminate fasteners altogether
  5. Use intermediate jigs
  6. Adopt parallel operations (see image below)
  7. Eliminate adjustments
  8. Mechanization

Preview (Click to enlarge)
  SMED Instructions
Adobe PDF Format
Adobe PDF
SMED Instructions
  Set up time Analysis
Microsoft Excel Format
Microsoft Excel
Set up time Analysis
  Set up time Analysis Completed Example
Microsoft Excel Format
Microsoft Excel
Set up time Analysis Completed Example
  Changeover Analysis
Microsoft Excel Format
Microsoft Excel
Change over analysis
USD $19.95
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