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This website aims to provide you with all of the information that you will need to run your own SMED
implementation and achieve those quick changeovers. Through this site you will find step by step guides to
implementing SMED, hints, graphics and examples of what can be done.
The time that the machine or process is idle (The least precise as it takes no account of slowing down the
first production part nor getting up to speed to create good parts of the next batch.)
The time taken from the last good part of batch A to the first good part of batch B (This is the usually
accepted definition for a changeover.)
The time taken from normal running speed of batch A to achieving normal running speed for batch B (This
definition allows for any fine tuning and adjustments that have to be made before your reach full production
speed.)
In manufacturing, changeover is the process of converting a line or machine from running one
product to another. Changeover times can last from a few minutes to as much as several weeks in the
case of automobile manufacturers retooling for new models. The terms set-up and changeover are
sometimes used interchangeably however this usage is incorrect. Set-up is only one component of
changeover. Example: A soft drink bottler may run 16oz glass bottles one day, perform a changeover
on the line and then run 20oz plastic bottles the next day.
Clean-up
Clean-up product, materials and components from the line. It may range from minor, if only the label of a package is
being changed (for example from an English to a Spanish label) to major, requiring complete disassembly of the
equipment, cleaning and sterilizing of the line components in the case of an injectable pharmaceutical product.
Set-up
Set-up is the process of actually converting the equipment. This may be achieved by adjusting the equipment to
correspond to the next product or by changing non-adjustable "change parts" to accommodate the product. Typically it
will be a combination of both.
Start-up
Start-up is the time spent fine tuning the equipment after it has been restarted. It is characterized by frequent
stoppages, jams, quality rejects and other problems. It is generally caused by variability in the clean-up and set-up or
by variability in the product or its components.
How to Define a Quick Changeover
Whichever definition that you use for your changeovers you need to stick to it and ensure that everyone
understands how it is being measured so that you don’t have issues in understanding the progress that you
are making.
Origins of SMED
SMED is a lean manufacturing tool that has evolved out of the Toyota Production System (TPS). When
Toyota initially started to try to compete with the American auto manufacturers after world war II they had a
major disadvantage. Where the American companies would often have many press tools and machines
which were constantly run and dedicated to individual body panels and components, Toyota had a shortage
of presses.
These presses would often take upwards of 24hours to changeover from one body panel to the next and as
such Toyota’s chief production engineer Taiichi Ohno assisted by Shigeo Shingo a consultant from the
Japanese Management Association set out to reduce these setup times. By 1970 they had reduced the setup
times on 1000 ton presses from over 4 hours to less than 3 minutes.
Benefits of SMED
While it may seem that the greatest benefit from being able to have a quick changeover would be having
less downtime from a machine and thus greater machine utilization the actual benefits are far greater than
this;
Increased capacity – less time on setups means more available working time
Reduced batch sizes – Shorter setup times mean you can run smaller batches more often
Improved production flow – Vital for Just in Time (JIT) production as part of Lean manufacturing.
Reduced stock and WIP (Work in Progress) – See below regarding stock reduction
Increased flexibility – much easier to slot in that urgent order or to service multiple customers or part
numbers
Lead times reduced – often lead times of weeks can be slashed to a day or two
Improved quality – if there are problems you will quickly know and quantities will be reduced
Waste reduction – less scrap and rework associated with setups as well as quality improvements
Less space and handling equipment – less stock so reduced need to store and move
Costs reduced and Profits increased
The most important benefits are the improved flow and flexibility which come with the huge benefit of
greatly reduced stock holdings. As you implement quick changeovers you do not continue to run large
batches but change to running smaller batches more often So you maintain the amount of time spent on
setups and production and turn that into smaller batches;
SMED Example
The most obvious example of the SMED process outside of manufacturing is that of a formula one quick tire
changeover. The formula one pit stop is known by just everyone and each team will compete to ensure that
they have the fastest possible time. However this is a far from typical changeover and each team will have
invested large amounts of money in the equipment they use and the design of the individual components.
But when you compare the likely 15 to 20 minutes that you will take to change a tire to their sub 10 seconds
performance it is an amazing achievement, but would you trust your car with only one bolt holding the
wheel in place?
Your SMED implementation need not cost huge amounts of money, many of the savings come purely from
being organized and having everything in the right place.
The table below shows how if you use the time saved in reducing setups for running additional batches
rather than just increasing run times you can reduce the amount of stock that you have to hold significantly.
Reducing Batch Sizes Through SMED
Using the example above you could go from running a full months stock of a component each day to
running just a day’s worth of product This can have a significant impact on the amount of stock that your
business holds.
As the graphic above shows; if you routinely run a full month of each product you will hold 15 days stock
on average. If you reduce that to running just one days stock then you will hold just half a day of stock!
Imagine the savings that would mean for most businesses! Not just with regards to the actual material costs
but with regards to space and handling equipment.
Smaller batch sizes also mean that the time between running material and it being used are dramatically
reduced meaning that quality problems are identified quicker and are going to be contained to much smaller
quantities.
Elements of a setup
There is no such thing as a standard setup but if there were maybe it would look a little like the diagram
above. We would spend our time in everything from preparing the next tooling and equipment to making all
of the adjustments to ensure that our process ran well. The trouble is where is it that we need to start when
implementing any type of quick changeover program?
Click on each stage to be taken to the relevant page explaining how to conduct that part of the process.
You will also need to understand the following;
If Someone told you that you could easily reduce your changeover times by as much as 50% without
spending any money or even having to work very hard you would probably tell them that they are talking
rubbish. But that is what most companies achieve just through this initial analysis of the setup when
implementing SMED. We often spend well over half of our changeover doing things that we could have had
prepared before hand; so why do we do it – because we have always done it that way!
What are Internal and External Setup Activities?
When you conduct a setup on a process or a machine there are some parts of your setup that can be
conducted while the machine is running and others that require that the equipment is stopped. Internal setup
activities are those that require the process to be at a standstill before you can conduct them safely while
external activities can be done while the process is still running.
SMED Stage 2
The next stage of our SMED implementation is to look at the external activities that we have separated and
to standardize them so that they are done efficiently for each set up. Click the link to discover how to
standardize external activities.
In the first stage of our quick changeover process we used videos and flow charts to identify all of those
activities within our setup that can be conducted as external activities; that is they can be done while the
process is still running. So these are things such as fetching tooling and instructions. This enables us to have
all of these activities prepared before we stop the process and begin the main part of our quick changeover.
By this point we will often have put everything in place to save at least 50% of the downtime caused by our
changeover.
In this second stage of our SMED implementation we will look at organizing and standardizing these
external activities to ensure that they are done quickly and efficiently. Failure to do this will result in us still
searching for tooling and other items when the machines are at a standstill giving us a longer than necessary
changeover.
Standardizing External Activities can reduce the amount of time spent on them.
What do we mean by standardize this process?
I am sure that within the videos that you watched of the setup that there were times when the people doing
the setting had to wander off to find something or were searching for something in a draw or some other
wasteful and time consuming activity. If you videoed more than one shift or different setups performed by
different people I am sure that you also saw things done in a different order or even using completely
different methods.
The idea of this step of the process is to get organized and to define exactly how everything should be done
so as to eliminate some of the waste and to ensure that things are done in the best (safest, efficient) way.
Another Lean tool known as 5S is very helpful at this stage. 5S is a technique that is used to organize a work
space so that everything is there and in the right place to be used efficiently. It is also used to produce
standardized processes and to create a highly visual workplace which makes elimination of problems very
easy.
You can read a step by step guide for 5S through this link; 5S Guide
Using the analysis from the first stage we can produce a simple checklist for all of the information, tools and
materials that should be available, this should cover everything such as;
Documentation
Production orders
Standard Operating Instructions
Engineering Drawings
Production Dies, Jigs and Fixtures
List of what is required
Check all clean and in working order
All components and fixings (list them all)
Tools
List all tools (screwdrivers, Allen keys, etc)
Check all clean and working order
Materials
List all (Type, size, grade etc.)
Right quality, quantity and right location
Standardize the External Activities using checklists and improving layout
For those items that are used on a regular basis (often called “runners”) we can find locations where or very
close to where they are actually used so that they are at hand when we need them. The use of tooling
shadows or clearly labeled shelves can make it very obvious if these items are missing so they can be found
long before we start the changeover.
Part specific tools and equipment can be gathered on a trolley prepared before we start the actual
changeover. Again a well labeled trolley with tooling shadows and the like can ensure that everything that
we need is there before we start.
Organize using 5S principles
This stage of SMED may not in itself appear to shave any time off the changeover, however by having
everything organized and documented you will avoid the problems that would otherwise occur. Without
clear instructions, organization and a clear work space you ca guarantee you would regularly hit delays
within your setups.
The second stage saw us standardize external setup elements ensuring that not only do we have a quicker
changeover but that it is done repeatably and also preventing the creep back to where we were before;
something that always tends to occur if we don’t document our new ways of working.
The next step is to look at all of the internal setup activities and consider how we can convert them into
external activities allowing us to further reduce the actual down time of the process while we setup.
The Internal activities have to be done while the process is at a standstill, so obviously we are seeking to
minimize this time. The engineers amongst you will be keen at this point to jump in and to try to make every
stage of our changeover easier and quicker but you need to ask yourself first does this step even need to be
done as an internal step? Is there a way that we can convert this step into an external activity that can be
done while the process is still running? We need to see if we can remove some of these internal changeover
steps rather than just trying to make them quicker. Often by the time we get to the end of this third stage it is
not unusual to have eliminated 75% or more of the original setup time.
Preset cutters within a tool using fixtures so that they are ready to use
Use intermediate jigs allowing dies and fixtures to be mounted and adjusted prior to fitting
Preheating of Dies /materials (Formula one tires are heated to race temperature before fitting)
Additional set of changeover parts available pre-cleaned rather than having to clean and re-use what
is currently in use.
If you find something that is not on the list then do it and let us know.
Once you have your new external activities ensure that you add them to your check sheets and standardized
ways of working that you produced in the second stage of our SMED implementation. Far too often people
get carried away with the success of making so many improvements that they forget to document everything
and six months later things have drifted right back to where you started.
The next stage of SMED is to look at improving the internal changeover activities themselves and to see
what can be improved to further reduce the time for our quick changeover. So our next stage is to improve
internal setup activities for SMED.
In the previous stages of our SMED implementation we have identified and separated the internal and
external activities of our changeover, internal activities being those that have to be done while the machine
is shut down and external being those that can be safely completed while the machine is still running. We
have then gone through the internal setup activities to convert them to external activities. At this point we
have probably managed to save around 75% of our setup time.
Having managed to make significant improvements for our quick changeover we now need to look at
improving those activities that must be performed while the process is actually idle. This is the point that
most engineers want to jump to straight from the start; but if they did they would lose out on all of the
savings that we have already made.
This stage will see us look at and begin to improve those activities that have to be undertaken while the
machine is stopped, this will be the controlling factor in reducing our time further. This means looking at
every stage of what we do and asking ourselves why we are doing it and if we can do it better.
One of the commonest things that delays all setups is the use of bolts and screws to fix jigs and fixtures, as
Shigeo Shingo once said; “only the last turn of the bolt tightens, the rest is motion (waste).” How often have
you seen a setter struggling with an spanner to tighten a bold for a minute or more and then repeating it a
dozen more times.
To eliminate the waste of tightening bolts there are a number of options that we can implement; these can
range from boltless clamping using toggle clamps or offset cam levers through to pear shaped holes that can
be slid over bolts and then only need a single turn to tighten.
The pictures below shows several options that you could use;
Quick release clamping using a single turn of a bolt.
We should now have improved the internal setup activities significantly compared to where we were when
we first started our SMED implementation. However we now need to go and take another look at our
external setup activities as we will probably find now that they are more time consuming than the rest of the
setup. You will find the next stage of our single Minute Exchange of Die implementation by clicking the
link to our final SMED Stages to improve external setup, implement automation and eliminate changeover
completely.
I will deal with the final stages of SMED in one single post as these stages are fairly simple and related. We
have already by now significantly reduced our Setup, hopefully already down to single minutes. The aim of
SMED or Single Minute Exchange of Die is to get the changeover down to less than 10 minute.
SMED Stage 5;
You will probably be at a stage now where the activities that are performed while the process is still running
take longer than the actual quick setup process that you now have. This should be worked on using the same
ideas that you have already used for your internal activities to ensure that you reduce the time that is spent
on these external activities;
Once you have reduced your external activities once again ensure that your process if fully documented to
ensure that everyone follows best practice at all times. You do not want to have differences between
different operators or shifts.
Use 5S principles to improve your external changeover time
SMED Stage 6
Before embarking on any form of automation you should very carefully consider the cost benefits of what
you will do as well as the final step of our quick change over program which is to actually eliminate the
changeover completely. If the cost benefits are not going to justify using automation you should revisit the
previous steps of your Single Minute Exchange of Die program to see if you can achieve any additional
changes.
The other reason for Automation is of course safety is you are handling heavy or hazardous materials in
which case automation is a very valid way of moving forward.
I have rarely seen the need for a changeover to be automated, the few times that it has been automated it has
come with automated loading and unloading of components so people have actually been freed from the
process to conduct other work within the process.
SMED Stage 7
Have dedicated machines; often it is cheaper to have many smaller dedicated machines than one all singing
all dancing super machine that does everything.
Design Modifications; remove the need for multiple components through the design process
Modify tooling to produce multiple parts; consider an “airfix” style injection molding tool that produces a
whole set of components rather than multiple sets of one component.
Like automation eliminating the setup can be an expensive and often time consuming option so it is
something that will require a cost benefit analysis.
If you are having any problems with your quick changeover process feel free to contact us here for help and
advice in ensuring that you achieve your setup goals. If you feel that any of the information here is unclear
or you would like to add anything then feel free to use the contact page to get in touch.