SMED

In manufacturing industries, there’s always that need to provide customers with the maximum product and services quality possible while reducing waste at the same time. For this reason, a number of methodologies have been introduced; one of which is Single Minute Exchange of Die (SMED). Single Minute Exchange of Die (SMED) provides a rapid and efficient way of changing over a manufacturing process from running the current production process to running the next (production process). This rapid changeover has been consistently proven to be the key to reducing waste, production time, thereby improving flow.

However, bear in mind that the phrase "Single Minute" does not necessarily mean that all change over, set ups and start up time should take only one minute. Rather, it is in there to stress the need that change over, set ups and start up time should take less than 10 minutes; in fact, “single minute” is short for "single digit minute".

Implementing Single Minute Exchange of Die (SMED):

Single Minute Exchange of Die (SMED) was first introduced by a Japanese quality management pioneer by the name Shigeo Shingo. Shigeo Shingo recognised that there are eight main techniques that should be highly considered when implementing SMED. However, before the list of techniques, note that external setup can be done without the line being stopped whereas internal needs the line to be stopped. They are:

• Separate internal from external setup operations
• Convert internal to external setup
• Standardize function, not shape
• Use functional clamps or eliminate fasteners altogether
• Use intermediate jigs
• Adopt parallel operations (see image below)
• Eliminate adjustments
• Mechanization

Effects of Implementing Single Minute Exchange of Die (SMED)

So how effective is the implementation of Single Minute Exchange of Die (SMED) to any form of manufacturing process? Basically, SMED and quick changeover programs have many benefits for manufacturers. From reducing downtime associated with the changeover process to reducing the waste created during start up. Additional benefits include:

• SMED increases machine work rates from reduced setup times even if number of changeovers increases
• It eliminates setup errors while allowing trial runs to reduce defect rates
• Improved quality from fully regulated operating conditions in advance
• Increased safety from simpler setups
• Simplified housekeeping from fewer tools and better organisation
• Stockless production drives a company’s capital turnover rates
• Reduction in footprint of processes will reduce inventory, thereby freeing workshop space
• Productivity increases over time
• SMED Lowers set up and other expense
• It lower skill requirements since changes are now designed into the process rather than a matter of skilled judgement
• Elimination of unusable stock from model changeovers and demand estimate errors
• Goods are not lost through deterioration
• Ability to mix production gives flexibility and further inventory reductions as well as opening the door to revolutionised production methods.

Another process management methodology that is known to be closely related to Single Minute Exchange of Die (SMED) is a more difficult or complex concept. It is called One-Touch Exchange of Die (OTED), which stresses that changeovers can and should take less than 100 seconds (that is approximately 1.67 minutes) at all times.

5S - Process or a large part of Kaizen
Lean Manufacturing - Helps develope lean process
Poke-Yoka - Process to help find average timing