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Quick Change Over

Also know as SMED


(Single Minute Exchange of Dies)

Lean means no waste


Toyota had few $ in invest in capital
machinery and equipment and quickly
realized the lost $ in the lack of machine
utilization

Previous lectures cited change over as waste


and potential Kaizens

Some references

Machinery and equipment utilization


US Industry spends 15% to 20%
of its dollars in machinery and equipment
Accountants want machinery running 24/7
without interruption (clearly impossible)
To get the return on investment
Aluminum extrusion process

This report is a dream for most industries

Footnote
During the 1950 & 60s
in the US Auto companies
Ford GM Chrysler
American Motors
Packard
Routinely shutdown for the month of August for
change over.
Laid everyone off, while they changed over
to the new model dies (doors, fenders, hoods)

A progression of improvements
SDED - Single day exchange of
dies
SHED - Single hour exchange of
dies
SDED - Single ten minutes
exchange of dies
SMED - Single minute exchange of
dies

1
Preliminary
Three stages of SMED

Internal
:Prelimina
ry
& external
setup not
separated

Separate
internal
and
external
setup

Convert
internal
setup to
external
setup

Stream
line all
aspects of
setup
operation
s

Quick Changeover is explained in four


steps.

1
Preliminary
Three stages of SMED

Internal
Preliminar
y
& external
setup not
separated

Separate
internal
and
external
setup

Convert
internal
setup to
external
setup

Stream
line all
aspects of
setup
operation
s

It is important to recognize that operations


are delayed, stopped or interrupted while
hunting for stuff
to run the job.

1
Preliminary
Three stages of SMED

Internal
Preliminar
y
& external
setup not
separated

Separate
internal
and
external
setup

Convert
internal
setup to
external
setup

Stream
line all
aspects of
setup
operation
s

Setup operations is made up of four steps.


1. Preparation and after-process adjustments
2. Mounting and removing blades, tools, and parts
3. Measurements, settings, and calibrations
4. Trial runs and adjustments

The time for internal setup with the machine


stopped can be reduced by 30% to 50%.
Example: PREPARING
Have a checklist that lists everything
required to setup the next operation
Get every thing required staged

PREPARATION
1. A checklist lists everything required
to setup the next operation
Tools
Specifications
Workers required
Proper values for
the operation
conditions such as
temperature,
pressure, feed, and
current

1. Use a checklist so
you dont have to
chase after things
Items for the next
setup are checked
off as you get them
while the machine
running
So it is an external
setup

Example: PREPARING
Get everything required
Everything needed to run the job
Staged and ready

ER crash cart

http://www.bing.com/videos/se
arch?
q=crash+cart&view=detail&mid
=CB1E44FA2DA76F0A85D4C
B1E44FA2DA76F0A85D4&first
=0

All tools and parts are ready before the


machine is running

Preparing and transporting while the machine


is running, the time for internal setup, with
the machine stopped can be reduced
by 30% to 50%.
Example
Die change over is staged and ready

1
Preliminary
Three stages of SMED

Internal
Preliminar
y
& external
setup not
separated

Separate
internal
and
external
setup

Convert
internal
setup to
external
setup

Stream
line all
aspects of
setup
operation
s

Internal means While the machine runs


External means While the machine is not
running. Setup, transporting, storing

Improve the transportation of parts and tools

To shortened the time that


the machine must be shut
down, items are moved
during external setup.

So new parts and new


tools are transported to
the machine before the
machine is shut down for
changeover.

Until the new stuff is


installed, and the machine
started up for the new
product, the old stuff must
not be put away.

A useful external changeover tool!

Elastic bandage
manufacturer
(video-later)

1
Preliminary
Three stages of SMED

Internal
Preliminar
y
& external
setup not
separated

Separate
internal
and
external
setup

Convert
internal
setup to
external
setup

Stream
line all
aspects of
setup
operation
s

Reexamine operation to see if any


steps are wrongly assumed to be
internal setup
Convert these steps to external setup

Example - using jigs to center the die External


When setting up the press
the die must be positioned
in the center of the bolster
Traditionally to get the fit
the ram is slowly and
cautiously lowered since
the die could be destroyed
if not done properly
Very operator time
consuming

The V shaped notches in


the jigs match exactly

Using jigs to center the die - internal

A jig is attached to the machine


And a jig is attached to the die

Using jigs to center the die

The V shaped
notches in the jigs
match exactly

This simple operation


that reduces errors
and setup time

Zero Change OverBefore

improvement
30 minutes
For a small press, large dies were
difficult to position
Most of the weight came from the
shanks
The first step was to eliminate the
shanks

Zero Change OverBefore

improvement
30 minutes
For a small press, large dies were
difficult to position
Most of the weight came from the
shanks
The first step was to eliminate the
shanks

A drawer type cassette


was created

Before

With the weight gone


creating the cassette followed

Before
After
improvement
improvement
30 minutes
25 seconds.
Adding the swivel locks
completed the improvement

1
Preliminary
Three stages of SMED

Internal
Preliminar
y
& external
setup not
separated

Separate
internal
and
external
setup

Convert
internal
setup to
external
setup

Stream
line all
aspects of
setup
operation
s

Basic elements of each setup are


analyzed in detail.
Specific principles are applied to
shorten each step

Streamlining examples
One turn functional clamping methods

One turn functional clamping methods


Nuts & bolts for attaching
tools & dies are the enemy
Get lost
Get mismatched
Take too long to tighten
15 threads are to provide friction when used for
fastening,
But for setup turning another 14 turns is a waste.
Use functional clamps

One turn functional clamping methods


U-slots
Insert the bolt
head into the
dovetail on the
machine bed.
Slide the bolt
into the U-slot

One turn functional clamping methods


The Clamp
The clamp method
is one-step time
saving motion.

One turn functional clamping methods

C-shaped washer
One turn time
saving motions.

One turn functional clamping methods


C-shaped washer
One turn time
saving motions.
In most cases
these one turn
methods can be
permanently
attached to the
machine so nothing
gets lost or
mismatched

One turn functional clamping methods


Split thread methods
Grooves are cut along
the length of the bolt to
divide it up into three
sections.
Mating grooves are cut
into the nut.
The mating nut and bolt
grooves are lined up
and one turn engages
both to lock the piece in
place

Preliminary

Three stages
Internal
Preliminar
y
& external
setup not
separated

of SMED
Separate
internal
and
external
setup

Convert
internal
setup to
external
setup

Stream
line all
aspects of
setup
operation
s

Quick Changeover is explained in four steps


Video and painstaking breakdown separate,
stop watch time, and chart each step before
starting your SMED