REDUCTION IN SETUP TIME BY APPLYING PRINCIPLES OF

REDUCTION IN “SET-UP TIME” BY APPLYING PRINCIPLES OF S. M. E. D (SINGLE MINUTE EXCHANGE OF DIE)

WHAT IS S. M. E. D ? • JAPANESE METHODOLOGY. • BY SENSEI ‘SHIGEO SHINGO’. • REDUCES ‘SET-UP CHANGEOVER TIME’, DRASTICALLY. • REVOLUTIONIZES BASIC CONCEPT OF ‘SET-UP CHANGE’.

BENEFITS OF SMED Quick set up change over schedule adherence CUSTOMER SATISFACTION Short Batches Response Time Inventories Defects

APPLY SMED PHASE -I PRINCIPLES 100% 50 % SMED 50 % BEFORE AFTER PHASE - I

PHASE -II PHASE - I 100% PHASE - II 20 % BEFORE AFTER 50 % 30 %

STEPS-1 -PRESENT STATUS VIDEO SHOOTING

STEP 2 INTERNAL & EXTERNAL SET UP TIME • 1. INTERNAL SET-UP. • THOSE ACTIVITIES WHICH NEED STOPPING THE EQUIPMENT, . • LIKE, REMOVAL AND MOUNTING OF MOLD. • 2. EXTERNAL SET-UP. • THOSE ACTIVITIES WHICH CAN BE CARRIED OUT WITHOUT STOPPING THE EQUIPMENT.

REPLACING A WHEEL OF A CAR 1. Find Jack, Tommy bar, spanner, in short tools. 2. Place & locate below the car at the required place. 3. Loosen the nuts. 4. Remove the wheel 5. Bring another wheel 6. Locate & insert new wheel 7. Tighten the nuts. 8. Remove the jack & collect the tools. 9. Place it back in the car 10. Final tightening of the nuts

ABILITY TO DISTINGUISH • MASTERING THE DISTINCTION BETWEEN INTERNAL AND EXTERNAL SETUP IS THE PASSPORT TO ACHIEVING S. M. E. D. PHASE I

Wheel Change Activities

STEP 3 -ACTIVITY DISTRIBUTION GRAPH

STEP 4 - PARALLEL OPERATIONS • CARRY OUT PARALLEL OPERATIONS. • ESPECIALLY ON THE INTERNAL SET UP TIME. • TOTAL ‘MAN-MINUTES’ MAY REMAIN THE SAME. • BUT ‘ELAPSED’ TIME IS DRASTICALLY REDUCED.

METHODOLOGY ADOPTED 5. Analysis of the Film & Brain storming for idea generation carried out continuously for 14 Hrs by the Team. TOTAL TIME PHASE I INTERNAL EXTERNAL PLANNING PARALLEL PHASE II REDESIGN TOOLS, FIXTURES, METHODS ADVANCE PARALLEL CONVERT

STEP 5 ELIMINATE - ‘SEARCHING THINGS’. • APPLY 5 -S PRINCIPLES. • PEEP - PLACE FOR EVERYTHING AND EVERY THING IN PLACE. • ALL TOOLS, TACKLES ARE IDENTIFIED. KEPT PROPERLY, SAY IN TROLLEY. • CLEANING TOOLS ARE ALSO USED.

SOME SUCCESS STORIES

RESULTS - GPEL

Results - GGL

SMED-IMPLEMENTATION STEPS • SMED AWARENESS PROGRAM FOR • SENIOR MANAGEMENT - 1 hr • OPERATING PEOPLE - 1. 5 hr • SMED IMPLEMENTATION - PHASE I PROGRAM • FORMATION OF CROSS FUNCTIONAL TEAM. • VIDEO-SHOOTING OF PRESENT METHOD. • INPUTS ABOUT HOW TO INTERPRET FILM. • IDENTIFY ‘INTERNAL & EXTERNAL TIME’. • PREPARE ACTIVITY DISTRIBUTION GRAPH.

SMED-IMPLEMENTATION STEPS • KNOW ABOUT THE POTENTIAL OF IMPROVEMENT IN PHASE I & II. • SETTING OF TARGET BY TEAM - PHASE I & II. • ACTION PLAN ON TIME FRAME.

SMED-IMPLEMENTATION STEPS • REPORTING, MONITORING AND COMPARING FORMAT GIVING ALL THE DETAILS, AS ON DATE , MONTHLY AND YTD BASIS. • FIVE MINUETS MEETING AT THE END OF EVERY SET UP CHANGE. • STANDARDIZATION OF PHASE I METHOD. • START PHASE II.

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