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Title: Equipment Efficiency: Availability, Quality and SMED


1
Equipment EfficiencyAvailability, Qualityand
SMED
  • Operations Analysis and Improvement
  • 2009 Spring
  • Dr. Tai-Yue Wang
  • Industrial and Information Management Department
  • National Cheng Kung University

2
Presentation
  • It has become increasingly important to
    economically manufacture products in smaller
    product batches.
  • Product lead times must be kept as small as
    possible.
  • Product customization continues to increase.
  • Number of parts produced on manufacturing systems
    continues to increase
  • Batch sizes have been reduced.

3
Presentation
  • Companies should be as agile and flexible as
    possible.
  • Reduce machine set-up time times to minutes
    instead of days or hours.
  • The Single-Minute Exchange of Dies (SMED) is a
    clear easy-to-apply methodology.
  • Good results in many cases very quickly.
  • It was developed by Shigeo Shingo in Japan from
    1950-80s.
  • Achieve good results without costly investments.

4
Introduction
  • Set-up process.
  • Time required to go from the end of the last good
    part from one batch to when the first good part
    of the following batch is produced.
  • The trials needed to obtain the first good
    product are considered part of the set-up process.

5
Introduction
  • SMED -gt Single-Minute Exchange of Die.
  • Designed so that the set-up process should be
    made in less than 10 minutes.
  • During the 1960s the set-up time for a large
    stamping press could take more than a full day.
  • It is possible to achieve reductions around 60
    of the original set-up time.
  • In reductions of about 90 the project costs
    become significant.
  • It is not always necessary to reduce the machine
    set-up process.
  • Tires on your personal vehicle vs. car racing.

6
Introduction
  • SMED is contemplated in the Just-in-time and
    in the 20 keys methodologies (key number 5).
  • SMED improves the availability rate as well as
    the quality rate.
  • This set-up time includes the trial phase.
  • Startup losses included in the quality rate are
    produced in this trial phase

7
Basic steps in a set-up process
  • Four typical classes of set-up operations
    regardless the type of the machine or equipment.
  • Prepare, adjust and check (new materials and
    tools).
  • Remove old tooling and install new tooling on the
    machine.
  • Measure, set and calibrate (fixtures, tools and
    tooling).
  • Produce initial parts (production trials) and
    adjust the machine..

8
Basic steps in a set-up process
  • Prepare, adjust and check operations focus on
    making sure that the tools and materials that
    will be used for set-up are available when the
    set-up is scheduled.
  • Produce initial parts and adjust depends on the
    set-up specialists know-how.

9
Traditional strategies
  • For high volume manufacturing applications, the
    set-up process duration was not particularly
    important.
  • Manufactures could afford to have customers
    waiting.
  • Production was scheduled based on manufacturing
    needs.
  • These set-ups hardly affected the products
    price.
  • Shutdown production facility to for two weeks
    while machines and tools were set-up for new
    model year production.
  • Today, manufacturing lot sizes have decreased.
  • Manufacturing flexibility needs to increase.
  • Same quantity -gt increased part variety and with
    smaller delivery quantities.

10
Traditional strategies
  • The possible production of defective parts at
    set-up coupled with the increased frequency of
    set-up has forced manufacturers to make more
    products than required.
  • In order to reduce set-up process affects,
    companies usually use two different strategies.
  • Try to make the set-up as fast as possible.
  • Increase the production lot size.

11
Skilled based strategies
  • Many companies have used set-up specialists to
    reduce changeover and set-up times.
  • Skilled in the operation of specific machines.
  • Familiar with the needed tools and methods to
    carry out the exchange.

12
Skilled based strategies
  • Dependence on these specialists can be strong.
  • Skill that a set-up specialist needs.
  • Set-up process complexity.
  • Not all the tasks that set-up specialists carry
    out are critical.
  • The specialist can get help from the machine
    operator.

13
Large batches based strategies
  • The larger the batch size is, the smaller the
    impact of the set-up time will be on the
    production cost of each part.
  • Cost per part is based on the company cost
    system.
  • The system shares all company costs to each
    product.
  • There is a section that depends on the time to
    manufacture and also on its respective set-up
    time.
  • If the lot size is large, the set-up time effect
    is spread out more than if the lot size is small.

14
Large batches based strategies
  • The higher the set-up time, the bigger the profit
    will be.
  • This reasoning supports the lot size increasing.
  • Some companies only accept orders that exceed
    certain lot sizes.

15
Large batches based strategies
  • If set-up time and production time were about the
    same magnitude
  • it would not make sense to search for large
    lots size.

16
Economic Lot Size strategy
  • Large set-up times -gt large batch size.
  • Increase in inventory cost and potential loss for
    products becoming obsolete.
  • The economic lot size is a direct relationship
    between the inventory cost and the set-up cost.
  • The effect of the set-up cost decreases
    exponentially according to the increase of the
    batch size.
  • This hypothesis is based on a constant set-up
    time.

17
Economic Lot Size strategy
  • As set-up cost decreases, the economic lot size
    would also decrease until reaching the unit
    product lot size.
  • It would be profitable to only accept orders made
    up of one article a batch size of one!

18
SMED methodology
  • 1950 in Toyo Kogyo factory.
  • Shingo discovered that the exchange of an 800 ton
    press was delayed because of a missing screw.
  • Two types of operations in the process of change.
  • Those that should be carried out with the machine
    running producing parts from the previous lot.
  • Shingo called these activities External set-up.
  • Those that required the machine and for it to be
    idle while they were performed.
  • Shingo denoted as Internal set-up.

19
SMED methodology
  • In 1957 Shingo improved the SMED methodology.
  • Placing an extra table in a Mitsubishi Company
    machine.
  • Convert some of the internal set-up tasks to
    external set-up operations.
  • Shingo reduced the set-up time for a screw
    machine manufacturer from 8 hours to 58 seconds.
  • At the Mitsubishi Company from 24 hours to 2
    minutes and 40 seconds.

20
SMED. 4 conceptual stages
21
Preliminary stage
  • Studying the current set-up process because
    simply put what is unknown cannot be improved.
  • Know the process, the variability and the
    cause(s) that produce this variability.
  • Collect values for the set-up times.
  • set-ups can be frequent or sporadic.
  • By means of the time study process.

22
Preliminary stage
  • the SMEDs goal is not to eliminate specialists
    job.
  • set-up specialist opposition can lead to project
    failure.

23
Separating internal and external set-up
  • Classify set-up operations according to the given
    definition of external and internal set-up.
  • It takes into account the same operations and
    duration included in the current method.
  • Without improving any particular operation.

24
Separating internal and external set-up
  • Assure that the operations defined as external
    set-up can all be carried out with the machine
    running.
  • Time to get the necessary tools and materials is
    not allocated to the operators.
  • It is possible to reduce the exchange time by as
    much as 60 without any capital investments.

25
Converting internal set-up to external set-up
  • The set-up process time reduction from the first
    stage can be very significant but is not where
    SMED ends.

26
Converting internal set-up to external set-up
  • This stage examines two important aspects.
  • Re-evaluate the internal set-up.
  • Check or see if some of them were considered
    erroneously as internal.
  • Look for alternatives that allow internal set-up
    to be carried out in whole or in part as external
    operations.
  • For example, is it possible to screw a die to a
    press before placing it inside the press chamber?

27
Converting internal set-up to external set-up
  • This stage will require an economic investment.
  • Carry out a cost justification.
  • Sometimes the investment will be necessary in
    spite of the economics.

28
Converting internal set-up to external set-up
  • Other important aspect to consider.
  • New process or system reliability.
  • The possible appearance of new operations.
  • The benefits and possible risks of the new
    process.
  • It is possible to achieve set-up process time
    nearing ingle minutes (lt 10 minutes)

29
Streamlining all aspects of the set-up process
  • This stage tries to improve all the set-up
    operations.
  • Both internal and external.
  • Trying to eliminate some operations.
  • SMED methodology recommends that one follows
    systematically these four stages.
  • Common sense -gt not be invested in operations
    that previously have not been optimized.

30
Streamlining all aspects of the set-up process
  • stage 3.
  • Improvement of the external set-up operations.
  • Revisit of the internal activities that have not
    been possible to convert into external.

31
First stage tools
  • Numerous time wastes take place in many set-up
    processes.
  • Materials are moved to the warehouse with the
    machine stopped.
  • Tools and dies are supplied late, or incorrectly.
  • Tools and dies that are not needed, are taken
    back to the supply room before starting the
    machine.

32
First stage tools
  • Some required screws and tools were not collected
    during the set-up process.
  • Some nuts are just too tight when trying to
    remove them.
  • It is necessary to eliminate all these wastes.

33
First stage tools
  • Try to answer certain questions before starting
    the set-up.
  • What has to be done before starting the change?
  • How many screws are necessary in order to fix the
    die? Of what type?
  • What tools are necessary? Are they prepared for
    proper conditions?
  • Where should the tools be placed after using them?

34
First stage tools
  • A group of visual controls have been developed.
  • Checklist.
  • Questionnaire that should be checked before each
    set-up process.
  • Verify in advance that all elements that should
    be prepared are in fact ready and available.
  • Can be universal for all products changeover or
    specific for each product.

35
First stage tools
  • Check panel placed next to the machine.
  • Small number of tools or exclusive tools.
  • The worker can visually check if all the
    necessary tools are located.
  • In some check panels the tools are silhouetted.
  • Another strategy is to code the tools with two
    stickers.
  • A sticker is placed in the machine and another is
    placed on the tool.

36
First stage tools
  • Function checks.
  • The checklist or the check panel do not show the
    die and tools status.
  • Material inlays.
  • Special devices for checking the molds before
    placing them in the machine.
  • If the company does not own one -gtsecond stage.

37
First stage tools
  • Parts and tools transportation improvements.
  • Transportation from the warehouse to the work
    area should be carried out before the exchange
    begins.
  • traditional press exchange process
  • Removes the used mold -gt loads it in a crane -gt
    takes it to the warehouse -gt loads the new mold
    -gt place it.
  • new changeover process
  • Load the new mold -gt leave it next to the
    machine -gt take out the mold -gt leave it next to
    the machine -gt loads up the new mold -gt set the
    machine into operation -gt carry the used mold to
    take it to the warehouse.

38
First stage tools
  • This new changeover looks like it takes longer
    than the traditional method.
  • According to Shingos definition of set-up time,
    the time with the machine stopped is drastically
    reduced.

39
Second stage tools
  • The second stage usually runs parallel with the
    third stage.
  • SMED methodology offers some recommendations that
    facilitate complex cases studies.
  • Movements around the machine should not be
    questioned.
  • Will be analyzed in the third stage.
  • It is not that some operations will be
    eliminated.
  • There are several methods broadly intended to
    enhance the set-up process.

40
Endless material method
  • When a reel is empty, it should be removed and
    replaced with a full one.
  • Rolling mill or on packing machines.
  • The changeover time of reels could potentially be
    eliminated if the end of a reel is welded or tied
    to the beginning of the following one.
  • The product made with the welding seem would be
    scrape.

41
Endless material method
  • Temporary containers.
  • If it is not possible to weld or tie the reels to
    carry out the changeover operation.
  • Save set-up time considerably because they
    eliminate the movements to locate and bring in
    the new reel.
  • If the reels allow it, it might be possible to
    tie the previous reel with the following reel and
    with a simple turn, carry out the exchange.

42
Second stage tools
  • Press die preheat.
  • There are devices that heat the molds up before
    being placed in the machine.
  • The main concern in this case is labor safety.
  • Function standardization.
  • Standardize some measures (height and depth).
  • The set-up process should be as safe as before.
  • The quality of the manufactured pieces should not
    be adversely affected.
  • Add new functionalities or features to the mold.

43
Second stage tools
  • Tools duplication.
  • Have two or more identical elements (cranes,
    tools, pallets,) to reduce the set-up time.
  • A single six pack is as easy to handle as a
    single can of soda.
  • With a double crane it is possible to prepare the
    next mold and to extract the previous one without
    the need of removing and placing the molds again.

44
Third stage tools
  • The improvement or elimination of an operation
    requires reengineering some aspect of the product
    or process.
  • it is possible to make the operation in a
    different way?
  • Is this operation necessary?
  • Is this procedure the most appropriate?

45
Third stage tools
  • Up to this stage, external operations have not
    been analyzed.
  • Will the set-up specialist have enough time?
  • Schedule the changeovers so that the specialists
    are not needed at the same time in two machines.
  • Internal operations can be improved.
  • Analyze in detail the movements around the
    machine.
  • Determine the optimal number of workers that
    should take part in the set-up process.

46
Improving tool storage. Indicators strategy
  • Begin with the 5Ss.
  • Organize tool storage in an efficient way.
  • Keeping high use items close for easy access.
  • Organizing the tooling so that it is easily
    located and identified.
  • The 5S methodology offers a common orientation
    when choosing the coding standards.

47
Parallel operations
  • For large machines, it is necessary to carry out
    operations at the front of the machine as well as
    at the back of it.
  • The worker can waste important set-up time when
    walking around the machine.
  • The set-up time and complexity can be reduced
    with the help of a second worker.

48
Parallel operations
  • Utilize a task map to indicate what operations
    will be carried out by each worker
  • Starting with the initial situation.

49
Parallel operations
  • Two workers executing the exchange in a parallel
    way.
  • Table shows task sharing and those tasks that can
    be carried out simultaneously as well as the
    times where the workers should be waiting.

50
Parallel operations
  • Allows the Lean thinker to discover which are the
    most important tasks that should be improved.
  • Labor safety, once again, is a priority in this
    type of synchronized work.
  • Safety mats that stop the machine when they are
    activated.
  • Confirmation buttons.

51
Third stage tools
  • One-Motion Method.
  • Perform more than one task simultaneously.
  • Electric and hydraulic connections.

52
Third stage tools
  • Functional clamps.
  • Devices that are used to passively hold an object
    in a fixed position with the minimum effort.
  • The SMED methodology seeks to eliminate the use
    of screws and nuts as fixing elements.
  • Pear-shaped holes.
  • U-shaped washers rings.

53
Third stage tools
  • Functional clamps.
  • C-shaped washers.
  • Guttered thread.
  • Single-movement method.
  • Reduce the tools variety.

54
Eliminating trials and adjustments
  • Can represent 50 of the total changeover time.
  • They are not only decreased but eliminated.
  • A set-point should be used instead of an
    adjustment.
  • Without applying the trial and error method.
  • The adjusting procedures must be written
  • The machine parameters value should be specified.
  • OTED (One Touch Exchange of Die).

55
Process Automation
  • The last resource after the successful
    implementation of the previous methods.
  • Process automation supposes high investments
    costs.
  • Regardless of its expensive implementation, in
    some cases it is the best alternative.

56
Zero changeover
  • When Shingo died in 1990, Sekine and Arai
    continued his work.
  • They tried to achieve set-up times of less than a
    minute.
  • They create a strategy called Zero changeover.

57
Zero changeover
  • The only way to achieve set-up times near to
    seconds was to automate the exchange process.
  • Represents large investments.
  • Many of the achieved improvements, came from
    ideas developed by Shingo.

58
SMED effects and benefits
  • Easier set-up process.
  • New changeover procedures.
  • Set-up process is simplified and easier to carry
    out.
  • Many of the operations can be carried out by the
    majority of the employees.
  • Increased safety also results from the improved
    changeover simplicity.
  • Eliminate defective parts.

59
SMED effects and benefits
  • On-hand stock production.
  • Manufacturing batch size can be decreased as
    well.
  • Work-in-process will decrease.
  • Mean time of material flow will decrease.
  • Lead time will decrease too because it is
    directly related with the time of material flow.
  • Workplace tasks simplification.
  • Tool coding, a clean and upstanding machine
    environment.
  • Easier to locate tools.

60
SMED effects. Productivity and flexibility
  • The main benefits.
  • Productivity.
  • Flexibility.
  • Productivity.
  • Decrease the machines load in order to increase
    the productive period.
  • SMEDs principal benefit is to increase
    flexibility as it will be show next.

61
SMED effects. Productivity and flexibility
  • Productivity increase.
  • SMED is an alternative among other methods
  • Increase in flexibility.
  • SMED is the only solution
  • Buying a new machine does not provide an increase
    on the flexibility.

62
SMED effects. Productivity and flexibility
63
Economic benefits
  • Economic benefits depend on the machine situation
    in which the SMED is applied.
  • Saturated machine.
  • Liberate the machine from its load time to
    increase the machine availability
  • The benefit takes place due to the economic
    margin in the sales increment.

64
Economic benefits
  • Not saturated machine.
  • The necessary time to carry out a production
    order will decrease.
  • Saved cost in the workforce.
  • If the goal is to increase flexibility can be
    impossible.
  • Qualitative benefits derived from SMED.

65
Summary
  • This chapter has presented a basic but helpful
    methodology to reduce the set-up time in a
    machine.
  • SMEDs methodology proposes the arrangement of
    the needed tools used in the set-up process
    before the machine finishes the previous lot.

66
Summary
  • The main benefit of the set-up time reduction is
    the increase in the flexibility of the
    production.
  • Nevertheless, the economic justification of a
    SMED project, focus on flexibility increment, is
    quite difficult.
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