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“Due to the set-up times, the tendency is to produce in batches that are larger than the order quantities. This supposedly utilizes the equipment more efficiently, reduces set-up costs, and reduces unit product cost. But any production in excess of immediate market demand ends up as finished-goods inventory. The result of producing these large batches in today’s competitive marketplace is poor customer service despite high levels of inventory.” — M. Michael Umble and Mokshagundam L. Srikanth
Single Minute Exchange of Die (SMED) is a methodology providing a rapid and efficient way of converting a process from executing one item to executing the next item. This rapid changeover is key to reducing batch sizes and improving flow.
Over a period of several years, Toyota reworked fixtures and components to maximize their common parts, minimize and standardize assembly tools and steps, and utilize common tooling. This reduced change-over time. Wherever the tooling could not be common, steps were taken to make the tooling quick to change.
The workshop presents the concept of SMED and how it can be used to reduce changeover times to enable shorter runs. The methodology can also be applied to minimise time lost in ‘critical windows’ in any operation.
Who should attend?
The programme is aimed at any personnel engaging in business process improvement
“This course was completely new to me and I found that with the proper tools anything can be achieved.” — Robert, Operations Manager
What will I learn?
- How traditional set-up activities and roles can be radically re-organised to reduce changeover time or time lost in a ‘critical window’
- To demonstrate significant time savings using SMED by means of a practical demonstration
- To ensure the participants can take an existing changeover process, break this down into SMED classifications and radically reduce the overall changeover time
- Changeover and Critical Time
- Traditional Setup Steps
- Classification of activities
- 5 SMED Process Steps
- Preliminary stage – data collection
- Internal and External activities
- Streamlining all activities
- Documenting procedures
- Typical SMED results
- Ideas for Improvement
Assessment and Certification
ETAC certificate of attendance.