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Quick Changeovers: The process of getting to SMED
Quick Changeover  ,[object Object],[object Object],[object Object],[object Object]
Changeover time: Definition The time elapsed between when the  last good piece   of product A  comes off and the  first good piece  of product B starts. Last good piece of product A First good piece of product B Total setup
SMED :  S ingle  M inute  E xchange of  D ie Concept that says all setups should and can take less than  10 minutes OTED: One Touch Exchange of Die Concept that says all setups should and can take less than  100 seconds ! What is “World-Class”  in Quick Changeovers?
What can focusing on QCO do for us? 85% 62% 41% 0% < 100 sec 9% 16% 17% 0% 100 sec – 5 min 5% 12% 20% 5% 5-10 min 1% 7% 12% 20% 10-20 min 0% 3% 10% 26% 20-30 min 0% 0% 0% 19% 30-60 min 0% 0% 0% 30% > 60 min 1988 Estimated 1980 1977 1976 Setup Time
Why is Changeover Time Important? Time (minutes) Available Time Process Time Actual Process (Up Time) 0   24   48   72  96  120 168 Sched. D/T Total Available Time Sched. D/T Sched. D/T C/OTime C/OTime Lost  Time
Goals of quick changeover ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Flow!
 
Step 1:List the current process and times
Machine running Machine running Last good piece of product A First good piece of product B Total setup Internal and external elements Step 2: Observe today’s setup
Observations ,[object Object],[object Object],[object Object],[object Object]
Observations ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
 
BPCS Trans – old roll 34 30 26 28 Cut material  Thread material Lift roll /engage chucks Position new roll Retrieve new roll Start Line – ~ 38 mins Operator Log – new roll Stop line – cut paper – tape cores Run new roll to winder Rethread – re-splice roll Start line – Splice Break Lower into cradle Splice new/previous roll Retrieve tape Stop line/ remove cores 38 36 32 24 22 20 18 16 14 12 10 8 6 4 2
Step 3: Separate & list  internal  and  external  elements. Internal External
Internal vs. External… This distinction is a   cornerstone  of setup reduction: What is the difference between external and internal elements? Internal elements: operations that  must  be performed while the machine/process is stopped External elements: operations that can be performed while the machine/process is running
BPCS Trans – old roll 34 30 26 28 Cut material  Thread material Lift roll /engage chucks Position new roll Retrieve new roll Start Line – ~ 38 mins Operator Log – new roll Stop line – cut paper – tape cores Run new roll to winder Rethread – re-splice roll Start line – Splice Break Lower into cradle Splice new/previous roll Retrieve tape Stop line/ remove cores 38 36 32 24 22 20 18 16 14 12 10 8 6 4 2
BPCS Trans – old roll 34 30 26 28 Cut material  Thread material Lift roll /engage chucks Position new roll Retrieve new roll Start Line – ~ 38 mins Operator Log – new roll Stop line – cut paper – tape cores Run new roll to winder Rethread – re-splice roll Start line – Splice Break Lower into cradle Splice new/previous roll Retrieve tape Stop line/ remove cores 38 36 32 24 22 20 18 16 14 12 10 8 6 4 2
Step 4: Convert internal to external Internal External
How can we convert internal to external ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
BPCS Trans – old roll 34 30 26 28 Cut material  Thread material Lift roll /engage chucks Position new roll Retrieve new roll Start Line – ~ 38 mins Operator Log – new roll Stop line – cut paper – tape cores Run new roll to winder Rethread – re-splice roll Start line – Splice Break Lower into cradle Splice new/previous roll Retrieve tape Stop line/ remove cores 38 36 32 24 22 20 18 16 14 12 10 8 6 4 2
Internal elements Machine running Machine running Last good piece of product A First good piece of product B Total setup External elements External elements Setup/changeover With these changes, your new setup/changeover should look like this:
Streamlined internal  elements Machine running Machine running Last good piece of product A First good piece of product B Total  setup External elements External elements Step 5: Streamline the Internal  Elements
Create parallel steps ,[object Object],[object Object]
26 -4 -2 Position new roll Stop line/ remove cores Lift roll /engage chucks Thread material Cut material  Splice new/previous roll Lower into cradle Start line – Splice Break Run new roll to winder Stop line – cut paper – tape cores Start Line @ ~20 BPCS Trans – old roll 34 30 28 Operator Log – new roll Retrieve tape Retrieve new roll  38 36 32 20 18 16 14 12 10 8 6 4 2
Create parallel steps Internal External
Reduce complexity and eliminate waste ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Adopt quick die changeover  (QDC) hardware ,[object Object],Use Hydraulic Clamps, Quick Grip Fasteners and Air Tools
Quick die changeover hardware ,[object Object],[object Object]
Streamlined internal  elements Machine running Machine running Last good piece of product A First good piece of product B Total  setup Streamlined  External elements Streamlined  External elements Step 6: Streamline the External Elements
Adopt functional standards ,[object Object],[object Object],[object Object],[object Object]
Step 7:   Create new process ,[object Object],[object Object]
BPCS Trans – old roll 34 30 26 28 Cut material  Thread material Lift roll /engage chucks Position new roll Retrieve new roll Start Line – ~ 40 mins Operator Log – new roll Stop line – cut paper – tape cores Run new roll to winder Rethread – re-splice roll Start line – Splice Break Lower into cradle Splice new/previous roll Retrieve tape Stop line/ remove cores 38 36 32 24 22 20 18 16 14 12 10 8 6 4 2
26 -4 -2 Position new roll Stop line/ remove cores Lift roll /engage chucks Thread material Cut material  Splice new/previous roll Lower into cradle Start line – Splice Break Run new roll to winder Stop line – cut paper – tape cores Start Line @ ~20 BPCS Trans – old roll 34 30 28 Operator Log – new roll Retrieve tape Retrieve new roll  38 36 32 20 18 16 14 12 10 8 6 4 2
Step 8:   Test new process ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Step 9:  Document new process ,[object Object],[object Object],[object Object],[object Object]
Chart changeover times ,[object Object],5  10  15  20  25  30  5  10  15  20  25  5  10  15  20  25 JAN  FEB  MAR 25 min 20 min 15 min 10 min 5 min 0 min ?
Step 10: Kaizen the C/O! SMED/Quick Changeover
SMED “Simulation” Situation:   You leave work, after a long day, you’re tired and anxious  to get home to dinner with your family. It’s raining (or snowing) out, the traffic is heavy, and you’re late. You are driving along the interstate, and suddenly discover your have a flat tire. Exercise: As a group, list the detailed steps you must go through to change your flat tire and get back on the road again.
SMED “Simulation” Situation:   You leave work, after a long day, you’re tired and anxious  to get home to dinner with your family. It’s raining (or snowing) out, the traffic is heavy, and you’re late. You are driving along the interstate, and suddenly discover your have a flat tire. Exercise: Ask the group how long this process typically takes.  Get several answers.
SMED “Simulation” Situation:   Now we’ll take a look At how “professionals” change tires, And how long it takes them.
[object Object]

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SMED-Observation Training

  • 1. Quick Changeovers: The process of getting to SMED
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  • 3. Changeover time: Definition The time elapsed between when the last good piece of product A comes off and the first good piece of product B starts. Last good piece of product A First good piece of product B Total setup
  • 4. SMED : S ingle M inute E xchange of D ie Concept that says all setups should and can take less than 10 minutes OTED: One Touch Exchange of Die Concept that says all setups should and can take less than 100 seconds ! What is “World-Class” in Quick Changeovers?
  • 5. What can focusing on QCO do for us? 85% 62% 41% 0% < 100 sec 9% 16% 17% 0% 100 sec – 5 min 5% 12% 20% 5% 5-10 min 1% 7% 12% 20% 10-20 min 0% 3% 10% 26% 20-30 min 0% 0% 0% 19% 30-60 min 0% 0% 0% 30% > 60 min 1988 Estimated 1980 1977 1976 Setup Time
  • 6. Why is Changeover Time Important? Time (minutes) Available Time Process Time Actual Process (Up Time) 0 24 48 72 96 120 168 Sched. D/T Total Available Time Sched. D/T Sched. D/T C/OTime C/OTime Lost Time
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  • 9. Step 1:List the current process and times
  • 10. Machine running Machine running Last good piece of product A First good piece of product B Total setup Internal and external elements Step 2: Observe today’s setup
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  • 14. BPCS Trans – old roll 34 30 26 28 Cut material Thread material Lift roll /engage chucks Position new roll Retrieve new roll Start Line – ~ 38 mins Operator Log – new roll Stop line – cut paper – tape cores Run new roll to winder Rethread – re-splice roll Start line – Splice Break Lower into cradle Splice new/previous roll Retrieve tape Stop line/ remove cores 38 36 32 24 22 20 18 16 14 12 10 8 6 4 2
  • 15. Step 3: Separate & list internal and external elements. Internal External
  • 16. Internal vs. External… This distinction is a cornerstone of setup reduction: What is the difference between external and internal elements? Internal elements: operations that must be performed while the machine/process is stopped External elements: operations that can be performed while the machine/process is running
  • 17. BPCS Trans – old roll 34 30 26 28 Cut material Thread material Lift roll /engage chucks Position new roll Retrieve new roll Start Line – ~ 38 mins Operator Log – new roll Stop line – cut paper – tape cores Run new roll to winder Rethread – re-splice roll Start line – Splice Break Lower into cradle Splice new/previous roll Retrieve tape Stop line/ remove cores 38 36 32 24 22 20 18 16 14 12 10 8 6 4 2
  • 18. BPCS Trans – old roll 34 30 26 28 Cut material Thread material Lift roll /engage chucks Position new roll Retrieve new roll Start Line – ~ 38 mins Operator Log – new roll Stop line – cut paper – tape cores Run new roll to winder Rethread – re-splice roll Start line – Splice Break Lower into cradle Splice new/previous roll Retrieve tape Stop line/ remove cores 38 36 32 24 22 20 18 16 14 12 10 8 6 4 2
  • 19. Step 4: Convert internal to external Internal External
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  • 21. BPCS Trans – old roll 34 30 26 28 Cut material Thread material Lift roll /engage chucks Position new roll Retrieve new roll Start Line – ~ 38 mins Operator Log – new roll Stop line – cut paper – tape cores Run new roll to winder Rethread – re-splice roll Start line – Splice Break Lower into cradle Splice new/previous roll Retrieve tape Stop line/ remove cores 38 36 32 24 22 20 18 16 14 12 10 8 6 4 2
  • 22. Internal elements Machine running Machine running Last good piece of product A First good piece of product B Total setup External elements External elements Setup/changeover With these changes, your new setup/changeover should look like this:
  • 23. Streamlined internal elements Machine running Machine running Last good piece of product A First good piece of product B Total setup External elements External elements Step 5: Streamline the Internal Elements
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  • 25. 26 -4 -2 Position new roll Stop line/ remove cores Lift roll /engage chucks Thread material Cut material Splice new/previous roll Lower into cradle Start line – Splice Break Run new roll to winder Stop line – cut paper – tape cores Start Line @ ~20 BPCS Trans – old roll 34 30 28 Operator Log – new roll Retrieve tape Retrieve new roll 38 36 32 20 18 16 14 12 10 8 6 4 2
  • 26. Create parallel steps Internal External
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  • 30. Streamlined internal elements Machine running Machine running Last good piece of product A First good piece of product B Total setup Streamlined External elements Streamlined External elements Step 6: Streamline the External Elements
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  • 33. BPCS Trans – old roll 34 30 26 28 Cut material Thread material Lift roll /engage chucks Position new roll Retrieve new roll Start Line – ~ 40 mins Operator Log – new roll Stop line – cut paper – tape cores Run new roll to winder Rethread – re-splice roll Start line – Splice Break Lower into cradle Splice new/previous roll Retrieve tape Stop line/ remove cores 38 36 32 24 22 20 18 16 14 12 10 8 6 4 2
  • 34. 26 -4 -2 Position new roll Stop line/ remove cores Lift roll /engage chucks Thread material Cut material Splice new/previous roll Lower into cradle Start line – Splice Break Run new roll to winder Stop line – cut paper – tape cores Start Line @ ~20 BPCS Trans – old roll 34 30 28 Operator Log – new roll Retrieve tape Retrieve new roll 38 36 32 20 18 16 14 12 10 8 6 4 2
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  • 38. Step 10: Kaizen the C/O! SMED/Quick Changeover
  • 39. SMED “Simulation” Situation: You leave work, after a long day, you’re tired and anxious to get home to dinner with your family. It’s raining (or snowing) out, the traffic is heavy, and you’re late. You are driving along the interstate, and suddenly discover your have a flat tire. Exercise: As a group, list the detailed steps you must go through to change your flat tire and get back on the road again.
  • 40. SMED “Simulation” Situation: You leave work, after a long day, you’re tired and anxious to get home to dinner with your family. It’s raining (or snowing) out, the traffic is heavy, and you’re late. You are driving along the interstate, and suddenly discover your have a flat tire. Exercise: Ask the group how long this process typically takes. Get several answers.
  • 41. SMED “Simulation” Situation: Now we’ll take a look At how “professionals” change tires, And how long it takes them.
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Notas del editor

  1. PURPOSE: To teach the SMED/Quick Changeover process SAY: SMED = Single Minute Exchange of Die DO: Ask why SMED/QCO is important? ADDITIONAL NOTES: C/O is waste because the product is not flowing while the process is being changed over.