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Similar a SBS - SMED Training (Set Up Reduction)
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SBS - SMED Training (Set Up Reduction)
- 1. SET-UP Reduction Workshop SS MM EE DD 1 Welcome !!! The Kaizen SMED Workshop
- 2. SET-UP Reduction Workshop SS MM EE DD 2 • Relentlessly Deliver to Our Customers Consistently Superior Value that Enables Symmetry Medical to Grow Better and Faster • Be Considered by All as the #1 Supplier, Employer and Investment of Choice • Become Clearly Recognized as the Industry’s Leader in Earnings and Sales Growth, as Well as a Premier Company, Distinctive and Successful in Everything we do SBS Mission Statement
- 3. SET-UP Reduction Workshop SS MM EE DD 3 Takt / Flow/ Pull Lean Mfg Six Sigma Total Quality WasteElimination(7Wastes) VariationReduction JIT TPM SMED Part Family / Process Cells 5 Ss (Housekeeping) & Visual Management Employee Involvement Defect Collection / Tracking & RCCA Industry’s ISO Quality System Green Belt - PQM Process Standardization BB - DOE Management Commitment 6σ 6σ 6σ Using an Inclusive Approach Team WorkTeam Work SPFSPF SMED Lean Sigma Strategy
- 4. SET-UP Reduction Workshop SS MM EE DD 4 Single Minute Exchange of 100 10 200 40 0 Dies, tools & fixtures 30 0 SSingleingle MMinuteinute EExchange ofxchange of DDiesies KKaizenaizen
- 5. SET-UP Reduction Workshop SS MM EE DD 5 SSingleingle MMinuteinute EExchange ofxchange of DDiesies KKaizenaizen Kiazen Team Ground RulesKiazen Team Ground Rules •Keep an open mind to change •Maintain a positive attitude •Never leave in a silent disagreement •Practice mutual respect every day •Treat others as you want to be treated •One person, one voice - no position rank •There’s no such thing as a dumb question •Understand the process and Just Do It!
- 6. SET-UP Reduction Workshop SS MM EE DD 6 Agenda ACTION • Why SMED • Terms and Concepts • Analyzing Set-Up Operations • Separate Internal and External • Checklists • Perform Function Checks • Improve Transport of Dies and Tools • Action
- 7. SET-UP Reduction Workshop SS MM EE DD 7 Why SMED ? • Optimize machine time • Make one-piece flow possible • Reduce leadtime
- 8. SET-UP Reduction Workshop SS MM EE DD 8 Set-up time and flexible manufacturing Traditional approach Flexible manufacturing Priority Strategy Set-up time Basic Hours Enlarge batches Less determining Lead time Quick reaction Inventory level Reduce batches Very important
- 9. SET-UP Reduction Workshop SS MM EE DD 9 This is a problem Given little consideration Traditional approach Present reality New approach Batches Set-up times Big batches Batch reductions One-piece flow Attack head-on SMED and batch size
- 10. SET-UP Reduction Workshop SS MM EE DD 10 Batch, SMED and Leadtime 50 30 25 9 5 Batch sizeNum ber ofbatches M achining : tim e per unit(hrs) M achining tim e / batch Set-up tim e/batch Inventory (equals 1 batch) Leadtim e (hrs) 10 10 10 10 10 10 5 5 1 1 1 2 2 10 10 4 4 4 4 4 40 20 20 4 4 10 5 5 1 1 Batch Set-up 10 10 Batch Set-up 5 10 Batch Set-up 5 5 Batch Set-up 1 1 Batch Set-up 1 5 M onthly requirem ent 10 10 5 5 1 A B A + B Today Tomorrow P R O G R E S S I O N
- 11. SET-UP Reduction Workshop SS MM EE DD 11 Defects Delivery DelaysProductivity Profitability Before SMED After SMED Why SMED ?
- 12. SET-UP Reduction Workshop SS MM EE DD 12 Summary Number of models Quantities by configuration Batch sizes Set-up frequency Single Minute Exchange of Dies lead time One-piece flow and
- 13. SET-UP Reduction Workshop SS MM EE DD 13 ACTION • Why SMED • Terms and Concepts • Analyzing Set-Up Operations • Separate Internal and External • Checklists • Perform Function Checks • Improve Transport of Dies and Tools • Action
- 14. SET-UP Reduction Workshop SS MM EE DD 14 Quick Changeover has many meanings depending upon what we are talking about, so lets define some terms: SSingleingle MMinuteinute EExchange ofxchange of DDieie
- 15. SET-UP Reduction Workshop SS MM EE DD 15 Changeover Time: The time between the last good piece off one run and the first good piece off the next run!!! SSingleingle MMinuteinute EExchange ofxchange of DDieie
- 16. SET-UP Reduction Workshop SS MM EE DD 16 INTERNAL SET-UP • Aspects of the SET-UP that can ONLY be performed while the machine is stopped. (Mounting and removing dies) • Minimize by separating from external, then find ways to reduce or convert to external. SSingleingle MMinuteinute EExchange ofxchange of DDieie
- 17. SET-UP Reduction Workshop SS MM EE DD 17 EXTERNAL SET-UP • Any aspect of the SET-UP that can be conducted while the machine is in operation (Transporting old dies to storage, conveying new dies to the machine, getting raw material, getting tools / gages, finding bolts / clamps). SSingleingle MMinuteinute EExchange ofxchange of DDieie
- 18. SET-UP Reduction Workshop SS MM EE DD 18 • A changeover that can be accomplished in less than ten minutes. Single Digit Changeover (SDC) SSingleingle MMinuteinute EExchange ofxchange of DDieie
- 19. SET-UP Reduction Workshop SS MM EE DD 19 One Touch Changeover (OTC) • A changeover that can be accomplished in less than one minute and is activated by a proactive action such as pushing a button. SSingleingle MMinuteinute EExchange ofxchange of DDieie
- 20. SET-UP Reduction Workshop SS MM EE DD 20 No Touch Changeover (NTC) • A changeover that can be accomplished in less than a minute automatically. SSingleingle MMinuteinute EExchange ofxchange of DDieie
- 21. SET-UP Reduction Workshop SS MM EE DD 21 ACTION Preliminary Internal and external setup not differentiated Ext Int Ext Int Ext Ext Int SMED’s Conceptual Stages and Practical Techniques 1 Separate internal and external setup 2 Convert internal setup to external setup 3 Streamline all aspects of setup operations 1.- Check List 2.- Function Checks 3.- Improved transport of parts and tools 1.- Advance preparation of operating conditions 2.- Function standardization 3.- Intermediary jigs 1.- Parallel operations 2.- Functional clamps 3.- Eliminating adjustments 4.- Mechanization 1.- Improved storage and management of parts and tools
- 22. SET-UP Reduction Workshop SS MM EE DD 22 SSingleingle MMinuteinute EExchange ofxchange of DDieie Typical Set-Up Operation and % of Set-Up Time before SMED improvements Clamping & Removing Dies and Tools 5% Preparing Materials, dies, fixtures 30% Centering & Determining dimensions of tooling 15% Trial processing & adjustments 50%
- 23. SET-UP Reduction Workshop SS MM EE DD 23 SSingleingle MMinuteinute EExchange ofxchange of DDieie ACTION The winners Circle
- 24. SET-UP Reduction Workshop SS MM EE DD 24 ACTION • Why SMED • Terms and Concepts • Analyzing Set-Up Operations • Separate Internal and External • Checklists • Perform Function Checks • Improve Transport of Dies and Tools • Action
- 25. SET-UP Reduction Workshop SS MM EE DD 25 Observe with a video If there is no one on the screen = waste Observation & analysis method
- 26. SET-UP Reduction Workshop SS MM EE DD 26 Describe, Analyze & Improve • DESCRIBE our set-ups in a standard fashion • ANALYZE our set-ups • IMPROVE our set-ups
- 27. SET-UP Reduction Workshop SS MM EE DD 27 SET-UP ANALYSIS FORM Current time Improvement No Task/Operation Internal External Internal External Current total Improve total Internal: Operations that necessitate the stopping of the machine External: Operations not requiring the stopping of the machine Key terms: ASSEMBLE, DISMANTLE, USE, TRANSPORT (EMPTY), TAKE, TRANSPORT (FULL), PUT DOWN, FIND, CHOOSE, INSPECT, DEPLACE (REPOSITION), HOLD , WAIT, LOOK FOR. Proposed time Analysis form
- 28. SET-UP Reduction Workshop SS MM EE DD 28 SMED: Analysis Steps SMED Graph EXT. INT. EXT. INT. EXT. INT. Current Improved Ideal Time 1 2 3 4 5 6 7 1 2 3 4 6 7 8 8 1 3 4 6 7 1. Identify the set-up 2. List every step 3. Measure the time required for every step 4. Distinguish between internal and external steps 5. Plot the current graph set-up time 6. Convert as many internal steps to external steps 7. Reduce the internal steps time 8. Reduce the external steps time 9. Plot the improved graph set-up time 10. Define the ideal set-up 11. Plot the ideal graph and strive toward it. Analysis steps
- 29. SET-UP Reduction Workshop SS MM EE DD 29 Graph analysis Setup Time Bar Chart 25 22 9.5 8 3 0 5 10 15 20 25 30 1 2 3 4 5 Observation Number Time Goal
- 30. SET-UP Reduction Workshop SS MM EE DD 30 Press Control Panel 1 2 8 5 3 7 6 4 9 Die Rack Raw Mtl. Incoming Carbon Scrap A286 Scrap 19 11 12 13 14 15 16 17 18 10 21 20 single worker Spaghetti DiagramSpaghetti Diagram Raw Mtl. Return
- 31. PROCESS FLOW ANALYSIS CHART PROCESS: # Activities AC TIVITY TR AN SPO R TATIO N IN SPEC TIO N D ELAY FILE D EC ISIO ND O C U M EN T C O M PU TER W orking Tim e (H rs) Elapsed Tim e (H rs) D istance ELIM IN ATE C O M BIN E SEQ U EN C E TR AIN IN GIM PR O VE CHANGES CURRENT W orking Tim e (H rs) Elapsed Tim e (H rs) D istance PROPOSED PLAYER: Tasks
- 32. SET-UP Reduction Workshop SS MM EE DD 32 ACTION • Why SMED • Terms and Concepts • Analyzing Set-Up Operations • Separate Internal and External • Checklists • Perform Function Checks • Improve Transport of Dies and Tools • Action
- 33. SET-UP Reduction Workshop SS MM EE DD 33 3 Techniques to separate Internal and External Set-Up tasks. • Checklists • Perform Function Checks • Improve transport of Dies and Tools Stage 1Stage 1
- 34. SET-UP Reduction Workshop SS MM EE DD 34 Checklists Everything required to Set-Up and run. • Tools, specifications and workers required. • Proper values for operating conditions. • Correct Documents (work order, part prints, First Article forms, etc.) Stage 1Stage 1
- 35. SET-UP Reduction Workshop SS MM EE DD 35 Checklist ExampleChecklist Example Employees Required: 1 Set-Up Checklist Date: Equipment: Stamper Part #: K51086-4 Operation: 303 Name: Tools Required 3/4 inch Wrench 5/16 Hex Key 3/4 inch Wrench Parts Required Stamp# 562-1587 Lay Out# 909-3578 Standard Operating Procedures SOP 001 (changeover)
- 36. SET-UP Reduction Workshop SS MM EE DD 36 Function Checks • Tell you whether the parts (tools, dies, product, etc.) meet the specification and are in perfect working order. • Should be done well in advance of the Set-Up so repairs can be made if something is incorrect. Stage 1Stage 1
- 37. SET-UP Reduction Workshop SS MM EE DD 37 Improved Transport of Parts and Tools • Transport new parts and tools to the machine before it is shut down to do the Set-Up. • Put away old parts and tools after the new parts and tools are installed and running. • If machine is manually operated, may require coordination with another worker assigned the task of transporting. Stage 1Stage 1
- 38. SET-UP Reduction Workshop SS MM EE DD 38 Action To begin a set-up analysis • Identify every step • Characterize every step • currently internal or external • Suggest how to transform the internal steps to external ones
- 39. SET-UP Reduction Workshop SS MM EE DD 39 ACTION • Convert Internal to External • Checklists • Perform Function Checks • Improve Transport of Dies and Tools • Streamline all aspects of the Set-Up Operation • Improve storage of Tools, Dies, Jigs & Gauges • Improve Transportation of Tools and Parts • Implement Parallel Operations • Functional Clamps • Eliminate Adjustments • Mechanization • Action
- 40. SET-UP Reduction Workshop SS MM EE DD 40 2 Steps to converting Internal to External Set-Up • Analyze the true functions and purposes of each operation in the current internal Set-Up. • Find ways to convert these internal Set- Up steps to External. STAGE 2STAGE 2
- 41. SET-UP Reduction Workshop SS MM EE DD 41 3 techniques for converting Internal to External Set-Up • Advance preparation of Operating Conditions. • Function Standardization. • Intermediary Jigs. STAGE 2STAGE 2
- 42. SET-UP Reduction Workshop SS MM EE DD 42 • Get the necessary parts, tools and conditions ready before Internal Set-Up begins. Conditions like temperature, pressure or position of materials can often be prepared externally. Advance preparation of OperatingAdvance preparation of Operating Conditions.Conditions.
- 43. SET-UP Reduction Workshop SS MM EE DD 43 Prepare tools ahead of time
- 44. SET-UP Reduction Workshop SS MM EE DD 44 Tools, gauges, accessories, information Next kit Preceding kit machine kit 1 kit 2 kit 3 kit 4 kit 5 Kits distributor Reassemble (kits)
- 45. SET-UP Reduction Workshop SS MM EE DD 45 • Analyze each individual function in the Set-Up process and decide which functions can be standardized. • Look again at the functions and think about which can be made more efficient by replacing the fewest possible parts. The quickest way to replace something is to replace nothing at all - or as little as possible. Function StandardizationFunction Standardization
- 46. SET-UP Reduction Workshop SS MM EE DD 46 DIE BDIE A 20 Standardized Clamping Height Standardized Shut Height Standardized Clamping Function Function StandardizationFunction Standardization 7 7 6 6 Standardized Pass Line Height on Dies that run strip stock 10 10
- 47. SET-UP Reduction Workshop SS MM EE DD 47 Function StandardizationFunction Standardization Use Jigs to position Tools / Dies Die or Tool Top View of MachineMachine Jig attached to Machine Jig attached to Die / Tool
- 48. SET-UP Reduction Workshop SS MM EE DD 48 Function StandardizationFunction Standardization Die Cassette System Die Shoe Stays in Press Die cassettes are the only tools changed
- 49. SET-UP Reduction Workshop SS MM EE DD 49 Die Cassette System Function StandardizationFunction Standardization
- 50. SET-UP Reduction Workshop SS MM EE DD 50 Function StandardizationFunction Standardization Die Cassette System
- 51. SET-UP Reduction Workshop SS MM EE DD 51 • Used to change Internal Set-Up tasks into External. • Standardized plates or frames that can be removed from the machine. • Next job is Set-Up on the Intermediary Jig while current job is running. Intermediary JigsIntermediary Jigs
- 52. SET-UP Reduction Workshop SS MM EE DD 52 Tool or part A Tool or part B Positioning Jig Intermediary JigIntermediary Jig clamps Intermediary JigsIntermediary Jigs
- 53. SET-UP Reduction Workshop SS MM EE DD 53 ACTION • Convert Internal to External • Checklists • Perform Function Checks • Improve Transport of Dies and Tools • Streamline all aspects of the Set-Up Operation • Improve storage of Tools, Dies, Jigs & Gauges • Improve Transportation of Tools and Parts • Implement Parallel Operations • Functional Clamps • Eliminate Adjustments • Mechanization • Action
- 54. SET-UP Reduction Workshop SS MM EE DD 54 Streamline all aspects of the Set- Up Operation. • All remaining External Set-Up operations are improved. • All remaining Internal Set-Up operations are improved. • Examine each operation’s function and purpose one more time. STAGE 3STAGE 3
- 55. SET-UP Reduction Workshop SS MM EE DD 55 Improve storage of Tools, Dies, Jigs and Gauges. • Tools should be stored at or near point of use in an identified spot. • Dies should be labeled with die number and storage location. • Dies / Tools that are used most frequently should be stored nearest to point of use. Streamlining External Set-Up Stage ThreeStage Three
- 56. SET-UP Reduction Workshop SS MM EE DD 56 Decrease walking time. Stop searching. machine machine BEFORE AFTER Tools, gauges, accessories, information Streamlining External Set-Up Stage ThreeStage Three
- 57. SET-UP Reduction Workshop SS MM EE DD 57 01 Die# 25695 04 Die# 481614 02 Die# 35892 03 Die# 124653 01 02 0403 Streamlining External Set-Up Tool / Die Storage Example Stage ThreeStage Three
- 58. SET-UP Reduction Workshop SS MM EE DD 58 Improve transportation of Tools and Parts. • Make sure we are using the proper device to transport Tools and Parts. • If delays occur while waiting for a fork truck, consider getting a dedicated die cart. Streamlining External Set-Up Stage ThreeStage Three
- 59. SET-UP Reduction Workshop SS MM EE DD 59 • Implement Parallel Operations • Use Functional Clamps • Eliminate Adjustments • Mechanization Streamlining Internal Set-Up Stage ThreeStage Three
- 60. SET-UP Reduction Workshop SS MM EE DD 60 Implement Parallel Operations • One person Changeovers on large machines mean wasted time and movement. • Parallel Operations divide the Set-Up operations between two or more people. • When using Parallel Operations it is important to maintain safe operations. Stage ThreeStage Three Streamlining Internal Set-Up
- 61. SET-UP Reduction Workshop SS MM EE DD 61 Press Control Panel 1 2 8 5 3 7 6 4 9 Die Rack Raw Mtl. Incoming Carbon Scrap A286 Scrap 19 11 12 13 14 15 16 17 18 10 21 20 single worker Before Parallel OperationsBefore Parallel Operations Raw Mtl. Return
- 62. SET-UP Reduction Workshop SS MM EE DD 62 Press Control Panel 1 2 8 5 3 7 6 4 9 Die Rack Raw Mtl. Incoming Raw Mtl. Return Carbon Scrap A286 Scrap 11 10 1 2 3 4 5 6 78 9 10 worker 2worker 1 After Parallel OperationsAfter Parallel Operations
- 63. SET-UP Reduction Workshop SS MM EE DD 63 BOLTS • In the SMED System Bolts are the ENEMY • Bolts Get Lost, they fall under machines. • Bolts Get Mismatched, they aren’t always standardized, matching up the right nuts and bolts take time. • Bolts Take Too Long To Tighten, the releasing and fastening only happen on the first and last turns. Stage ThreeStage Three
- 64. SET-UP Reduction Workshop SS MM EE DD 64 Functional Clamps • A Functional Clamp is a device that holds objects in place with minimal effort. • Most Functional Clamps can stay attached to the machine so there is nothing to get lost or mismatched. • Functional Clamp systems include one- turn, one-motion and interlocking methods. Stage ThreeStage Three
- 65. SET-UP Reduction Workshop SS MM EE DD 65 One-Turn Methods Pear-Shaped Hole Method Stage ThreeStage Three
- 66. SET-UP Reduction Workshop SS MM EE DD 66 One-Turn Methods C-Shaped Washer Method Stage ThreeStage Three
- 67. SET-UP Reduction Workshop SS MM EE DD 67 One-Turn Methods Clamp Method Stage ThreeStage Three
- 68. SET-UP Reduction Workshop SS MM EE DD 68 One-Turn Methods U-Slot Method Stage ThreeStage Three
- 69. SET-UP Reduction Workshop SS MM EE DD 69 One-Turn Methods Split Thread Method Nut Bolt Stage ThreeStage Three
- 70. SET-UP Reduction Workshop SS MM EE DD 70 One-Motion Methods Spring Stops Spring Stage ThreeStage Three
- 71. SET-UP Reduction Workshop SS MM EE DD 71 One-Motion Methods Cam Clamp Work piece Machine Cam Stage ThreeStage Three
- 72. SET-UP Reduction Workshop SS MM EE DD 72 One-Motion Methods Magnet Method Machine Magnet Work Piece Stage ThreeStage Three
- 73. SET-UP Reduction Workshop SS MM EE DD 73 Interlocking Method Tool Holder Tool Holder Machine Machine Stage ThreeStage Three
- 74. SET-UP Reduction Workshop SS MM EE DD 74 Eliminating Adjustments • Trial Runs and Adjustments can account for 50% of the time in a traditional Set-Up. • Three practical techniques for eliminating adjustments: • Use numerical scales and make standardized settings. • Make imaginary center lines and reference planes visible. • Use the Least Common Multiple system. Stage ThreeStage Three
- 75. SET-UP Reduction Workshop SS MM EE DD 75 Eliminating Adjustments Cut off to 4 inches, how to Set-Up ?? Shear operation Work Piece B l a d e Stage ThreeStage Three
- 76. SET-UP Reduction Workshop SS MM EE DD 76 Eliminating Adjustments Fixed Numerical Settings Shear operation Work Piece 12345 B l a d e Stage ThreeStage Three
- 77. SET-UP Reduction Workshop SS MM EE DD 77 Eliminating Adjustments Cutting Tool Center Line, (Invisible)Work Piece Lathe Visible Center Lines and Reference Planes How to set the Tool to the Center Line?? Stage ThreeStage Three
- 78. SET-UP Reduction Workshop SS MM EE DD 78 Work Piece Lathe Cutting Tool Center Line, (Invisible) Visible Center Lines and Reference Planes Mark Center Line on Housing Stage ThreeStage Three
- 79. SET-UP Reduction Workshop SS MM EE DD 79 Eliminating Adjustments Least Common Multiple System Limit Switch Material 4 different shaft lengths required, 5 ft., 7.2 ft., 8.4 ft. and 10 ft. Stage ThreeStage Three
- 80. SET-UP Reduction Workshop SS MM EE DD 80 Eliminating Adjustments Least Common Multiple System 1 2 3 4 Limit Switch Control Panel ON OFF ON OFF ON OFF ON OFF 5 7.2 8.4 10 Length Material Stage ThreeStage Three
- 81. SET-UP Reduction Workshop SS MM EE DD 81 RAM Upper Die Lower Die Least Common Multiple System Limit Switch Stage ThreeStage Three
- 82. SET-UP Reduction Workshop SS MM EE DD 82 RAM Upper Die -5 -6 -4 Lower Die Least Common Multiple System Limit Switch Rotary Stopper Stage ThreeStage Three
- 83. SET-UP Reduction Workshop SS MM EE DD 83 Mechanization • Should be considered only after every attempt has been made to streamline setups using the other techniques discussed. Stage ThreeStage Three
- 84. SET-UP Reduction Workshop SS MM EE DD 84 Synchronize Stages with GoalsSynchronize Stages with Goals Original Setup Stage one Stage Two Stage Three 50% 75% 90%
- 85. SET-UP Reduction Workshop SS MM EE DD 85 Action • Convert Internal Set-Up to External Set-Up • Streamline all aspects of the Set-Up Operation • Prepare for Wednesday’s Presentation • Prepare for Friday’s Final Presentation
- 86. SET-UP Reduction Workshop SS MM EE DD 86 Thursday’s Presentation • Set-Up Analysis Form • Set-Up Graph Analysis Form • Spaghetti Diagram (current condition) • Process Flow Analysis Chart • Stage 1 and 2 Improvements SSingleingle MMinuteinute EExchange ofxchange of DDieie
- 87. SET-UP Reduction Workshop SS MM EE DD 87 Final Presentation • Set-Up Analysis Form • Set-Up Graph Analysis Form • Spaghetti Diagram (before and after) • Process Flow Analysis Chart • Stage 1, 2 and 3 Improvements • Pictures SSingleingle MMinuteinute EExchange ofxchange of DDieie
Notas del editor
- Machines sit idle for hours due to set-ups and adjustments. Work Orders are large to absorb set-up costs. Delay: long lead times, customers must wait while we produce entire lot when they may only need a few. Inventory Cost
- Basic Hours (machine efficiency), when Set-Ups are long the Traditional approach would be to have big batches or lots to absorb the long Set-Up.
- Better Quality: SMED lowers defects by reducing set-up errors and eliminating trial runs. Higher productivity: Shorter change over time reduces down time, which allows more time to run parts. Higher Profitability: due to better quality, increased productivity, smaller batch sizes and increased inventory turns. Quicker delivery: Small lot production means less lead time and quicker production. Increased flexibility: we can respond more quickly to changes in customer demand.
- This is what we will be trying to reduce.
- 1 This step ensures that all parts and tools are where they should be and that they are functioning Properly. Also included in this step is the period after processing when these items are removed and returned to storage, machinery is cleaned, and so forth. In a traditional setup, parts of the preparation step are done after the machine is stopped, this step should be done as external setup-while the equipment is still running 2 This step includes the removal of parts and tools after one lot is processed, and the attachment of the parts and tools for the next lot. Generally the machine must be stopped to do this step, so it is internal setup. Notice that in this internal setup step the actual changing over-takes very little time compared to the other steps. 3 This step refers to all the measurements and calibrations that must be made in order to perform a production operation, such as centering, dimensioning, measuring temperature or pressure, and so forth. Although the equipment must often be stopped for this step, the SMED system teaches ways to do these tasks quickly by preparing while the equipment is still running. 4 In the final steps of a traditional setup operation, adjustments are made after a test piece is machined. The more accurate your measurements and calibrations are in the previous step, the easier these adjustments will be. Correct adjustment of the equipment is one of the most difficult tasks in a setup operation. In a traditional setup, the time needed for trial runs and adjustments depends on personal skill. Notice that this step accounts for about half of the time in a traditional setup. In a traditional setup the machine is not making good products until this step is finished, so it is considered part of internal setup. SMED teaches ways to eliminate this step completely, so that the machine makes good products right after it is started up.
- 1 This step ensures that all parts and tools are where they should be and that they are functioning Properly. Also included in this step is the period after processing when these items are removed and returned to storage, machinery is cleaned, and so forth. In a traditional setup, parts of the preparation step are done after the machine is stopped, this step should be done as external setup-while the equipment is still running 2 This step includes the removal of parts and tools after one lot is processed, and the attachment of the parts and tools for the next lot. Generally the machine must be stopped to do this step, so it is internal setup. Notice that in this internal setup step the actual changing over-takes very little time compared to the other steps. 3 This step refers to all the measurements and calibrations that must be made in order to perform a production operation, such as centering, dimensioning, measuring temperature or pressure, and so forth. Although the equipment must often be stopped for this step, the SMED system teaches ways to do these tasks quickly by preparing while the equipment is still running. 4 In the final steps of a traditional setup operation, adjustments are made after a test piece is machined. The more accurate your measurements and calibrations are in the previous step, the easier these adjustments will be. Correct adjustment of the equipment is one of the most difficult tasks in a setup operation. In a traditional setup, the time needed for trial runs and adjustments depends on personal skill. Notice that this step accounts for about half of the time in a traditional setup. In a traditional setup the machine is not making good products until this step is finished, so it is considered part of internal setup. SMED teaches ways to eliminate this step completely, so that the machine makes good products right after it is started up.
- Another Analysis Tool, make a spaghetti diagram of the current set-up condition.
- Analyze the current set-up condition using the Process Flow Analysis Chart.
- Stage I of SMED is Separation of Internal and External Setup Tasks. In other words, tasks that can be carried out while the machine is operating are separated from tasks that must be performed while the machine is stopped. Three practical techniques help us separate internal and external setup tasks: checklists, function checks, and improved transport of dies and other parts.
- A checklist helps you determine that you have all the tools you need for a particular operation. Checking items off the list before the machine is stopped helps prevent oversights and mistakes that otherwise might come up after internal setup has begun. Using a checklist also helps you avoid errors and multiple test runs later. It is very important to establish a specific checklist for each machine or operation. Using general checklists for an entire shop can be confusing. General checklists also tend to get lost and are often ignored.
- The next step, the function check, tells you whether the parts are in perfect working order. Function checks should be done well before setup begins so that repairs can be made if something does not work right. If broken dies, molds, or jigs are not discovered until test runs are done, a delay will occur in internal setup. Making sure such items are in working order before they are mounted will cut down setup time a great deal.
- Improved Transport of Parts and Tools Dies, molds, tools, Jigs, gauges, and other items needed for an operation must be moved between storage areas and machines, then back to storage once a lot is finished. To shorten the time the machine is shut down, transport of these items should be done during external setup. In other words, new parts and tools should be transported to the machine before the machine is shut down for changeover. Likewise, old parts and other tools should not be put away until the new parts are installed and the machine is started up for the next product. If the machine is automated, the operator may be able to handle the transport alone; other times, transport of parts and tools may require coordination with another worker who is assigned the task of moving. In either case, improving transport may involve taking a new look at your current procedure from the viewpoint of shortening machine downtime.
- Description of Stage 2 In Stage I of SMED, tasks that can be carried out while the machine is operating are separated from tasks that must be performed while the machine is stopped. But Stage I alone cannot reduce internal setup time into the single-minute range. For that, you must implement Stage 2, Converting Internal Setup to External Setup. There are two steps in Stage 2: 1.Look at the true functions and purposes of each operation in your current internal setup. 2.Find ways to convert these internal setup steps to external setup. An example of converting internal setup tasks to external setup is preheating molds that have always been heated only after setup has begun. Another example is shifting centering to an external task by doing it outside the machine on a standardized jig. The key to successful implementation of Stage 2 is allowing yourself to look at your current internal setup as if you are seeing it for the first time. Do not let old habits and beliefs get in the way of making changes.
- Three practical techniques help shift internal setup tasks to external setup. These techniques are: preparing operating conditions in advance, standardizing essential functions, and using intermediary jigs.
- Advance Preparation of Operating Conditions Advance preparation of operating conditions means getting necessary parts, tools, and conditions ready before internal setup begins. Conditions like temperature, pressure, or position of materials can often be prepared externally, while the machine is running. An example of advance preparation is preheating machine parts or materials-outside the machine-to the temperature needed for processing. Some companies conserve energy by using heat given off by other equipment for this task
- Function Standardization When tools or machine parts in a new operation are different from those in the previous one, operators must make time-consuming adjustments during changeover-often with the machine shut down. Standardization -keeping something the same from one operation to another-helps get rid of this internal setup. SMED uses a targeted approach called function standardization. It would be expensive and wasteful to make the external dimensions of every die, tool, or part the same, regardless of the size or shape of the product it forms. Function standardization avoids this waste by focusing on standardizing only those elements whose functions are essential to the setup. Function standardization might apply to dimensioning, centering, securing, expelling, or gripping, for instance. Implementing Function Standardization Implementing function standardization involves two steps: 1.Look closely at each individual function in your setup process and decide which functions, if any, can be standardized. 2.Look again at the functions and think about which can be made more efficient by replacing the fewest possible parts. The quickest way to replace something, of course, is to replace nothing at all-or as little as possible
- Standardizing the Clamping Function of Press Dies In the setup procedure for a press, adjusting the shut height of the die requires a lot of skill. Many people think it can only be done during internal setup, with the machine shut down. Function standardization of the part of the die that must be clamped to the machine can shorten internal setup time dramatically by making shut height adjustment unnecessary. Suppose you have two dies like the ones shown above. Die A has a 20-inch shut height and die B has a 15-inch shut height. Without function standardization, operators changing from one die to another would have to make a lot of adjustments on the machine in order to clamp on the new, differently sized die. Function standardization solves the problem by using simple shim devices to make the shut height and clamping height the same for both dies. Here's how it works: 1.Standardize Pass Line Height first, use blocks to make all die’s pass lines the same as the highest pass line. 2.Standardize Shut Height next, use blocks to make all die’s shut heights the same as the highest shut height. 3. Standardize Clamp Height next, use blocks to make all die’s clamp heights the same as the largest clamp height. Standardizing the clamping height makes it possible to use the same clamping bolts for both dies. This cuts out most of the adjustment work.
- Using Jigs to Center the Die When setting up a press, the die must be positioned in the center of the bolster. Some small dies have shanks on the top that must fit exactly into the shank attachment hole in the ram of the press. To get the die precisely centered for this, the traditional method was to inch the ram downward while aligning the shank and hole by sight. This was done slowly and cautiously, since the die could be destroyed if the ram was not correctly aligned. The operation was time-consuming and difficult. The operation can be improved with function standardization. A centering jig is attached to the machine so that the edge of the jig is a fixed distance from the center of the die and shank. This jig has V-shaped projections to the left and right of the center. Next, a second jig is attached to each die. This jig has two V-shaped notches that match the two projections on the centering jig. The width of this jig is set so that the shaft of the die will be perfectly centered from front to back when the die and jig are pressed against the jig on the machine. And when the V-shaped notches on the die jig interlock with the V-shaped projections on the machine jig, the die will be perfectly centered from left to right. Using this method, the shank and shank hole match up easily, even when the die is lowered at normal speed. Setting a die to center position becomes an extremely simple operation, which reduces errors and setup time a great deal.
- A third application of function standardization involves the use of a die cassette system. In this approach, the functions of a die or other part are separated into a mechanical function (applying pressure) and a product-forming function (making a particular change in the shape of the workplace). To take care of the mechanical function, the mechanical portion of the die is permanently attached to the machine -without the product-forming portion. The product-forming function is then made into a cassette device. just as an audio cassette can be exchanged according to what music you want to hear, die cassettes can be exchanged according to the function that needs to be performed. In other words, you might have a different cassette for each type of work your process requires and take them in and out of the machine as needed. In addition to standardizing the mechanical function of the operation, die cassettes are also lighter weight, easier to change over, and require less adjustment.
- An example of a Die cassette system used in 1518 and 1206. There is also a fixture that can be used to do a function check.
- Intermediary Jigs In many processes, intermediary jigs can be used to change internal setup tasks into external ones. Intermediary jigs are plates or frames of standard dimension that can be removed from the machine. While the die attached to one of these jigs is being used on the machine, the next die is centered and attached to another jig as an external setup procedure. When the first die is finished, the second jig - with the next die already attached and centered - is mounted on the machine. Intermediary jigs can also be used to set up workpieces and machine tools.
- In this stage, all of the remaining internal and external setup operations are improved. We do this by looking closely at each operation's function and purpose one more time. Implementing Stage 3 of SMED leads in nearly all cases to setups within the single-minute range.
- Streamlining External Setup External setup improvements include streamlining storage and transport of parts and tools so that these items are well-organized and ready for the next operation. In dealing with small tools, dies, Jigs, and gauges, it is vital to address issues of tool and die management. You need to ask yourself questions such as: What is the best way to organize these items? How can we keep these items maintained in perfect condition and ready for the next operation? How many of these items should we keep in stock?
- Operations for storing and transporting dies can be very time-consuming, especially when your company keeps a large number of dies on hand. Storage and transport can be improved by marking the dies with color codes and the location numbers of the shelves where they are stored, as shown. The shelves are also marked with this same "return address" information, making it easy to find dies and return them to their proper storage locations. In addition, the direction the dies need to face can also be taken into account during reshelving. Lastly, die storage and transport can be made much more efficient if the most frequently used dies are stored where they are easiest to retrieve the next time they are needed for an operation.
- Implementing Parallel Operations Machines such as large presses, plastic molding machines, and die-casting machines often require operations at both the front and back of the machine. One-person changeovers of such machines mean wasted time and movement because the same person is constantly walking back and forth from one end of the machine to the other. Parallel operations divide the setup operations between two people, one at each end of the machine. With two (or more) people, operations that were once completed in, say, 12 minutes might now take 4, thanks to eliminating the time spent walking back and forth. When setup is done using parallel operations, it is important to maintain reliable and safe operations and minimize waiting time. To help streamline parallel operations, workers develop and follow procedural charts for each setup. A procedural chart indicates the sequence of tasks each worker will perform, the time needed for each task, and when safety signals are to be given. Each time one worker has completed an operation, he or she must signal to the other worker-preferably with a buzzer, whistle, or light-to go ahead" or "wait." By following the procedural chart, everyone involved in the operation knows what to do and when.
- The "Before" slide above traces the single operator's footsteps. 1Cut off material 2Bring down ram 3Unbolt front of die 4Unbolt back of die 5Raise ram 6Remove die 7Take die to rack 8Remove old material 9Take to mtl. return 10Go to scrap barrel 11Return to scrap area 12Get new die 13Put die in press 14Bolt front of die 15Bolt back of die 16Get new raw Mtl. 17Install new raw Mtl. 18Get new scrap barrel 19Install new scrap barrel 20Raise ram 21Thread Die
- The "After" slide above shows the reduced number of steps involved in a parallel operation. Worker 1 Worker 2 1 Bring down ram 1 Cut off material 2 Unbolt front of die 2 Unbolt back of die 3 Raise ram3 Remove old material 4 Remove die4 Take to mtl. return 5 Take die to rack5 Bolt back of die 6 Get new die6 Go to scrap barrel 7 Put die in press7 Return to scrap area 8 Bolt front of die8 Get new scrap barrel 9 Get new raw Mtl.9 Install new scrap barrel 10 Install new raw Mtl.10 Thread Die 11 Raise ram
- People assume that because a nut has 15 threads, the bolt must be turned 15 times to tighten. In reality, those 15 threads are only there to provide the friction that holds the nut, bolt, and die or workpiece in place once the bolt is tightened. When the purpose of the bolt is simply to fasten or unfasten, turning the bolt another 14 turns is really a waste of time and energy; the releasing and fastening actually happens only on the first and last turns. To avoid this wasted time and energy, SMED uses devices called functional clamps.
- A functional clamp is an attachment device that holds objects in place with minimal effort. It may use a modified bolt or an entirely different kind of fastener that can be tightened or loosened quickly. In addition to being much faster, most kinds of functional clamps can stay attached to the machine, so there's nothing to get lost or mismatched.
- In the pear-shaped hole method, bolt holes are made into pear-shaped holes so that nuts on a lid, die, or other part can be loosened in one turn. Once the nuts are loosened, the part can be moved over by one bolt's width. The part can then be lifted off over the bolts without removing the bolts or nuts.
- In this method the plate being attached has a hole in it that is bigger than the nut, allowing the plate to be removed after the nut is loosened and the C-Shaped washer is moved out of the way. The C-Shaped washer remains attached to the plate.
- In this method the nut is loosened but does not need to be removed. A spring under the clamp keeps the clamp from falling. Clamp heights must be standardized first for this method to be used efficiently.
- In the U-slot method, a U-shaped slot is cut in the attachment edge of a die. By inserting the head of the bolt into a dovetail groove on the machine bed, then sliding the bolt into the U-slot of the die, the die can be fastened with one turn of the nut. Important Use T-Bolts, not T-Nuts with bolts. When T-Nuts are used with bolts you can not see if there is enough thread engagement. If too long of a bolt is used it can bottom out on the T-Slot, preventing sufficient clamp on the tool or part. This can also damage the T-Slot.
- In the split thread method, grooves are cut along the length of a bolt to divide it into two sections. Corresponding grooves are cut into the threads on the inside of the nut. Attachment is done by lining up the ridges of the bolt (where threads remain) with the grooves inside the nut (where the threads have been cutaway). The bolt is then slipped all the way into position and tightened by a one-quarter turn.
- Springs, for example, can be used to secure objects in pincer-type or expansion mechanisms. They can also be used as stops inside check pins on the inside diameter of an object. The example shows a spring-loaded check pin on a device for clamping gears onto a shaft.
- Magnetism is also very convenient as a one-motion method, especially when the entire surface of the workplace is to be machined and there is no room for attachment devices.
- Interlocking Methods Interlocking methods can be simply described as fitting and joining two parts together without the use of a fastener. For example, in the interlocking method shown, not a single bolt is used to clamp the tool holder to the machine. Instead, both the base plate of the tool holder and the machine cradle are provided with tapered surfaces. Attachment and centering precision are achieved by locking those tapered sections together. In other words, this interlocking method is simply a matter of fitting two parts together.
- Eliminating Adjustments Trial runs and adjustments can account for 50 percent of the time in a traditional setup. If adjustments can be eliminated, therefore, a lot of machine downtime can be saved. Bear in mind that when we talk about eliminating adjustments, that's exactly what we mean-eliminating, not just reducing. Eliminating trial runs and adjustments is done by making good settings before you ever start up the machine for the new operation. The number of trial runs and adjustments that will need to be made depends on how accurately (or inaccurately) you performed the centering, dimensioning, and condition setting in the earlier steps of setup. To eliminate adjustments, then, we need to refine and standardize how we carry out these earlier tasks. Three practical techniques for eliminating adjustments are: • Using a numerical scale and making standardized settings • Making imaginary center lines and imaginary reference planes visible • Using the Least Common Multiple (LCM) system
- Fixed Numerical Settings Eliminating adjustments requires operators to rely less on intuition and more on constant numerical values for machine settings. The fact is, as good as your intuition may be, it is still not exactly the same every time. The first step in doing away with adjustments is to make a graduated scale with marks indicating various settings, like the one shown on the next slide. By using a graduated scale, a setting of "4" is more or less the same each time that setting is needed. Although graduations help, however, they will not eliminate adjustments entirely when greater precision is required. Settings made by sight on a scale are usually accurate to within about .02 inch. When greater accuracy is needed, measuring instruments equipped with dial gauges should be used. Dial gauges are accurate to about .0004 inch. Digital numerical control devices are being refined and improved constantly, and you may find you can achieve even greater precision in your workplace. Another numerical setting method uses gages or shims-spacer blocks with fixed numerical dimensions to set a distance reliably each time. Gages can be used in various combinations, so that a few different gages can express a wide range of numbers.
- Visible Center Lines and Reference Planes In a traditional setup operation, center lines and reference planes may not be visible on the machine. This means that the correct position for a tool or workpiece must be found by intuition-or by trial and error. Making these center lines and reference planes visible is an effective strategy for eliminating these later adjustments.
- Least Common Multiple (LCM) System Many operations performed on one machine have elements in common, where similar things are done but with different dimensions, patterns, or other functions. The Least Common Multiple (LCM) system makes these common elements into a mechanism that can handle the different functions needed. During changeover, the mechanism stays in the machine, and only the function changes. In an LCM system, the function is changed by making a quick setting, such as by rotating tools on a spindle or flipping a switch. Thus two basic principles of the LCM system are: 1.Leave the mechanism alone and modify only the function. 2.Make settings, not adjustments. This example involves an operation in which a limit switch controls the end point of machining in the production of shafts. There are five shaft types, and the single limit switch has to be repositioned at a different point for each type. Every time a different type of shaft is processed, the switch has to be moved, test runs have to be conducted, and adjustments have to be made. In this time-consuming setup process, as many as four readjustments might be needed.
- Now look at the "After Improvement" portion. Notice that an individual limit switch has been permanently installed at each of the five needed positions. A master current switch controls the flow of electricity to each individual switch. This arrangement makes it possible to perform setup changes simply by pushing the master switch. In other words, setup now takes about one second.
- Only after every attempt has been made to improve setups using the methods we have already learned about should mechanization be considered. Bear in mind that the many basic techniques we have covered so far will often serve to reduce a two-hour setup to one requiring about three minutes. Mechanization may then further reduce the time by another minute or so. Avoid the mistake of jumping into mechanization from the start, however. There is a simple reason for this. Mechanizing an inefficient setup operation will achieve time reductions, but it will do little to remedy the basic faults of a poorly designed setup process. It is much more effective to mechanize setups that have already been streamlined.
- Only after every attempt has been made to improve setups using the methods we have already learned about should mechanization be considered. Bear in mind that the many basic techniques we have covered so far will often serve to reduce a two-hour setup to one requiring about three minutes. Mechanization may then further reduce the time by another minute or so. Avoid the mistake of jumping into mechanization from the start, however. There is a simple reason for this. Mechanizing an inefficient setup operation will achieve time reductions, but it will do little to remedy the basic faults of a poorly designed setup process. It is much more effective to mechanize setups that have already been streamlined.