The Lean Enterprise

Set-up Reduction/ Quick Changeover

Lean Foundations
Continuous Improvement Training
freeleansite.com

Introduction to Set-up Reduction /

Quick Changeover Concepts
based on a technique commonly called

SMED - Single Minute Exchange of Die

Objectives

Understand the concepts and principles of Setup Reduction.

Share some ideas and understand the benefits

of Set-up Reduction.

Apply the concepts, principles and techniques

of SMED to accomplish
Quick Changeovers !!

freeleansite.com

Team Beliefs
Safety comes first
Quality and superior customer satisfaction is our

ultimate goal
People are our most valued resource
Blameless environment
Continuous improvement is a way of life
Teamwork (customer, supplier, associates)
Integrity is never compromised

freeleansite.com

What is SMED?
SMED stands for:
Single Minute Exchange of Die

Ideally, set-up time should be

anything less than 10 minutes
Decreased set-up time;

reduces the need for inventory,

provides more flexibility and capacity,
enables us to better serve our customer!
freeleansite.com

Benefits of Quick Changeover

Less adjustments means less chance for errors
Elimination of trial processing reduces material waste
Preparation of operating conditions in advance helps stabilize
product quality
Increases scheduling flexibility/capacity
Reduces need for on-hand inventory
Improved service levels for customers
Smaller runs means less likelihood of large scale defect
problems in inventory
freeleansite.com

Set-up Time
D i es
Last
Good
Piece

s
Fixture
ls
Materia

Tools

Total elapsed
Time

freeleansite.com

First
Good
Piece

Set-up Time
Shigeo Shingo (wrote the book on SMED)
believed that:
any set-up time
can be reduced
by 59/60ths!

freeleansite.com

Set-up Time
There are two types of setup time:
Internal Set-up:
Those activities that must be performed while the
machine is shut down. (Work content done in
addition to Machine Time.)
Example: Removing dies and tooling
External Set-up:
Those activities that are performed while the
machine is operating.
Example: Preparing tooling for the next set-up
freeleansite.com

Set-up Reduction Process

1.

Observe and document the current set-up.

2.

Separate Internal and External elements.

3.

Improve each element.

4.

Observe and document the new set-up process.

5.

Standardize the new set-up procedure.

6.

Celebrate your success!!

freeleansite.com

Observe and Document the Current Set Up

A. Select a specific set-up for improvement
B. Identify a set-up kaizen team.
C. Observe the set-up process:

Video Record the set-up process

Complete the Set-up Operations Analysis

chart (before Kaizen).

D. Prepare a Pareto chart for each time category.

freeleansite.com

Record and Recommend

During this phase we:

Observe and document the existing set-up procedure
using
Time Observation and Video Recording techniques
- Analyze all work efforts
- Identify short-term solutions that can be
implemented with procedural changes, modifications to
existing fixtures and minor investment in tooling

Video Recording Tips

Collect background data
Select regular production Parts
Determine equipment and operation
Prepare/Evaluate site
Where does operator stand?
Where is the best position for the camera?
Is there adequate lighting?
Narrate
Describe what is happening when the
operator blocks the camera or leaves
the area.

Analyze the
Time Observation & Video
Review Time Observation and Video
with the team
Identify opportunities
Internal vs. External
Value Added Vs Non-Value Added
Normal vs. Abnormal
Seven Types of Waste
Automatic, Manual, Walking,
and Waiting times
Solicit ideas for countermeasures /
improvements

Observe and Document the Current Set Up

Set-up Operations Analysis Chart

Mach #

From

To

Area / Department

146

Model A

Model B

Machining Cell

Part #

Operation Time

Changeover Categories

Step No.

Changeover Element

Element

Elapsed

Internal

Pick-up tools from tool crib

(search)

19

19

19

Remove Fixture (Fixture

Change)

15

34

15

Look for Tools (Search)

39

Remove Fixture (Fixture

Change)

46

Clean & prepare subplate

(Fixture Change)

10

56

10

Prepare nex fixture (Fixture

Change)

20

1'16

20

Put on new fixture (Fixture

Change)

8
9

Before Kaizen Analysis

3456

Minutes

External

Improvement Plan
Mount hand tools on machine

Mount hand tools on machine

Establish common tooling for

all models.

Preset tooling (Tool Change)

1'48

Standardize procedures to
externalize this step.

11

2'14

12

Qualify 1st Piece (Gage)

12

2'26

12

2'26

2'26

2'11

Totals

Air wrench at machine .

Eliminate bolts - install
quick release. Design SMED
cart to load fixture.

15

Standardize procedures to
externalize this step.

1'42

Run 1st Piece (1st Piece)

11

Steel plugs for subplate.

Remove preset tools (Tools

Change)

1'59

Reduce

22

11

Internal to
External

See step 2.

1'38

Load new tooling (Tool

Change)

Eliminate

Air wrench at machine .

Eliminate bolts - install
quick release. Design SMED
cart to load fixture.

22

10

3/7/99

Goal of Improvement Plan

Waste
x

Date

Establish common tooling for

all models.

x
x

15
Standardize procedures to
externalize this step.

15

freeleansite.com

Observe and Document the Current Set-up

Searching
- Looking for tools, jigs, fixtures, etc.
Fixture Change
- Replacing one fixture with another
Tool Change
- Replacing existing tooling
Programming
- Making adjustments or changes to a CNC program in order to
accommodate the new set-up
Walk time
- The time an operator must walk to retrieve a fixture, tools etc.
1st Piece
- The time required to produce a good unit after the initial set-up
Gage
- The time required to qualify the 1st piece

freeleansite.com

Pareto Analysis on each Time Category

Set-up Pareto Analysis
80
70

time in min

60
50
40
30
20
10
0
Fixture Chg

Search

Tool Chg

1st Piece check

freeleansite.com

Calibrate Gauge

Separate the Elements

Internal:
Those activities that must be performed while
the machine is shut down.
Example: Removing dies and tooling
External:
Those activities that are performed while the
machine is operating.
Example: Acquire fixture/tools for next set-up
Both
Bothtypes
typesof
ofactions
actionsmust
mustbe
beseparated.
separated. Once
Oncethe
themachine
machineisis
stopped,
stopped,the
theassociate
associateshould
shouldnever
neverdepart
departto
toperform
performany
anypart
partof
of
the
theexternal
externalset
setup.
up.

freeleansite.com

Separate the Elements

Set-up Operations Analysis Chart

Mach #

Minutes
146

Part #

Operation Time
Step No.

Changeover Element

Before Kaizen Analysis

3 4 56
From

To

Area / Department

Model A

Model B

Machining Cell

Changeover Categories

Element

Elapsed

Internal

External

Waste

Improvement Plan

Mount ha nd t ools on ma chine

Mount ha nd t ools on ma chine

Pick-up t ools from t ool crib

(s ea rch)

19

19

19

Remove Fixt ure (Fixt ure

Cha nge)

15

34

15

Look for Tools (S earch)

39

Remove Fixt ure (Fixt ure

Cha nge)

46

Clean & prepare s ubpla t e

(Fixt ure Cha nge)

10

56

10

20

1'16

20

22

1'3 8

22

1'4 2

Es t ablis h common t ooling for a ll models .

6
7
8

Eliminate

Air wrench a t ma chine . Eliminat e bolt s ins t a ll quick relea s e. Des ign S MED ca rt
t o load fixt ure.

Internal to
External

x
x

S t eel plugs for s ubplat e.

S t anda rdize procedures t o ext erna lize

t his s t ep.
Air wrench a t ma chine . Eliminat e bolt s ins t a ll quick relea s e. Des ign S MED ca rt
t o load fixt ure.

Pres et t ooling (Tool Cha nge)

1'4 8

10

Loa d new t ooling (Tool Cha nge)

11

1'59

11

Es t ablis h common t ooling for a ll models .

11

Run 1s t Piece (1s t Piece)

15

2'14

12

Qualify 1s t Piece (Gage)

12

2'26

12

2'26

2'26

2'11

x
x
x

15
S t anda rdize procedures t o ext erna lize
t his s t ep.

15

Internal or External?
freeleansite.com

Reduce

S ee s t ep 2.

S t anda rdize procedures t o ext erna lize

t his s t ep.

Totals

3 /7/9 9

Goal of Improvement Plan

Prepare nex fixt ure (Fixt ure

Cha nge)
Put on new fixt ure (Fixt ure
Cha nge)
Remove pres et t ools (Tools
Cha nge)

Date

x
x
x
x
x
x

Develop Improvement Plan

5S +1 (6S) discipline is the key to quick changeover!
Every minute spent
looking for tools,
fixtures, drawings, dies,
jigs or other materials
adds to the set-up time.
A strong 5S foundation, with a point-of-use (POU)
methodology, will ensure that all required materials
are in place when needed, are clean, and in working
condition.
freeleansite.com

Develop Improvement Plan

Remember the Wastes ?
(refer to the 7Ws)

Defects

Punch Press

Over-Production (inventory)
Transportation
Tool Cart

Waiting
Inspection (mass)
Motion
Processing, itself

Storage area
for Dies
Tool Room

+ Unused Creativity

freeleansite.com

Develop Improvement Plan

Specifically:
A. Convert as much of the internal set
up to the external set up.
B. Eliminate or reduce the internal and
external set up.
C. Eliminate the adjustment process.

Ultimate Goal: Eliminate Set-up!

freeleansite.com

measure

separate

convert
freeleansite.com

external

external
internal

internal

external

Steps: Reduce internal work gradually

eliminate unecessary work

internal

reduce/eliminate (repeat)

Employ Improvement Initiatives

Once as much of the internal set-up has been
converted to external set-up and waste has
been eliminated:
standardize the external set-up actions
utilize quick fasteners
use supplementary tools at the point
of use (POU)

freeleansite.com

Employ Improvement Initiatives

Developing the Improvement Plan:

What must be done while the machine is

shut down?

What can be done while the machine is

running?

Challenge every element in the set-up !

Establish a sound 6S (5S+1) foundation.

freeleansite.com

Improvement Checklist an example

Station tools, jigs, dies, etc. near the machine. (POU)

Assure that all jigs, gauges, dies, tools, etc. function before
the set-up begins.

Perform as many External elements as possible prior to the

set-up.

Two people working together may reduce net set-up time

Use functional clamps: One turn/ One motion

Use visual control to eliminate adjustments.

freeleansite.com

Application Best Practices

1) Make minor modification to the
existing fixtures.
2) Implement Point-of-Use (POU) techniques.
3) Identify additional tooling to remove attachment
from internal to external.
4) Adopt standardized tooling.
5) Document time savings.

Application Best Practices - Continued

For example:
Slots in fixture and T-Bolts reduce
attachment time.
A new part holder reduced the time required to
load and unload parts to fixture. Swing hook
eliminated the need to remove nut from bolt.
Extra set slides allow detach to be completed on
external time.

Other ideas
1.

Quick Changeover begins and ends with the 5Ss.

2.

Change the Internal set-up into External, then improve

the remaining Internal set-up time.

3.

Bolts are our Enemies.

4.

If you have to use your hands make sure your feet stay
put.

5.

Dont rely on Special Fine-tuning skills.

6.

Standards are standard: they are NOT flexible.

7.

Standardize all SMED Operations

freeleansite.com

Ideas

The die heights of a punch press or molding machine can be

standardized by using the liner (spacer) so that stroke
adjustment will be unnecessary.
Source: Toyota Production System - Yasuhiro Minden

freeleansite.com

Ideas
Examples of Quick
Fasteners
Usually a bolt is the most
popular fastening tool.
But because a bolt fastens
at the final turning of the
nut can loosen at the first
turn, a convenient
fastening tool that would
allow only a single turning
of the nut should be
devised.
Source: Toyota Production
System - Yasuhiro Minden

freeleansite.com

Ideas

freeleansite.com

Ideas

freeleansite.com

Ideas
For example:
A slide clamp reduced the time required to load and unload parts to fixture.

2 hold-down clamps eliminated the need to tape parts during a glue-up operation.
Set slide allows quick (temporary) alignment of 2 parts.

Document the New Set-up

A. List each element on the Set-up
Operations Standard Chart (after Kaizen)
B. Video tape the new set-up procedure.
C. Record the set-up time for each element
D. Note areas for future improvement.

freeleansite.com

Standardize the New Procedure

Set-up Operations Standard

After Kaizen

Mach #

Minutes

From

To

Area / Department

Date

Part #
Operation Time
Step No.

Changeover Element

Element

Elapsed

Changeover Categories
Internal

External

Waste

freeleansite.com

Comments / Future Improvement Plans

Standardize the New Procedure

The Set-up Operations Standard chart will
become the basis for the new set-up
procedure.
Prepare the appropriate detail and work
instructions that will be included on the Setup Operations Standard chart.
Assure that all appropriate personnel are
trained in the new procedure.

freeleansite.com

The Lean Enterprise

Set-up Reduction/ Quick Changeover

Lean Foundations
Continuous Improvement Training
freeleansite.com