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a large part automated and requires manual work only in limited stages. One of the phases of the process which required manual work was setting up of the printing machines for a batch, or setting up involved while changing over between two different batches. It is required that the machine be cleaned of the colours/dyes from the previous run, as otherwise the colours required for the next run would mix with these and produce and undesired colour as a result. This cleaning of the machine and reloading it with the desired colours is done manually. We recommend the implementation of SMED concept for conducting this operation more efficiently: 1. Observe the setup operation: Firstly, we need to identify the activities that take place during the set-up. For this a video camera can be used, so as to capture an entire setup operation on film. A video camera is essential as it would be impossible to remember every minute step involved during the setup from memory or through documents of standard operating procedures. 2. Analyse the setup process and separate internal and external setup: Next, the video record should be watched by a team of experts, which includes people actually involved in the setup, as well as some members from other functional areas as well. The team need not be of more than 5-6 members. This step involves a crucial part of SMED that is the separation of internal setup and external setup. Internal setups are those which cannot be completed while the machine is running, for example cleaning of paint etc. External setupss are the ones which can be completed while the machine is running, for example assortment of paint containers and keeping them next to the machine for the next job. Further, the team should have a detailed discussion about the various tasks that are completed during the setup, and observe the manner in which tasks are done and the time taken for each task. Members from operational areas which precede and succeed this part of the process should be included in the team, so that they can analyze the impact of their actions on the printing operation as well as the other way round. Examples of external steps include: Getting materials for the next job (paper, inks, plates, etc.); Wrapping, strapping, packaging previously printed product. 3. Convert internal setup to external setup: The team can then go a step further to determine which of the internal setup activities can be converted to external setup. Some of these activities could be: Reviewing paperwork; Entering data on press sheets or into a computer; Cleaning the press area
the team will need to perform a trial run using the new procedure.4. . Follow through is critical A common. This will allow the team to critique its procedure and make adjustments. demands even. and raw materials can reduce and sometimes eliminate setup requirements. Streamline all activities in setup: External setup can be reduced by organizing the workplace properly. Revisit your SMED target areas again and again and continually drive out waste from the process. Nothing could be further from the truth. A new better way: When a new. if necessary. two people can perform a setup in less than half the time needed by a single person. business conditions change. parts. standardizing components. employees have new experiences and gain new skill sets. This trial should be videotaped the same way as before and from the same camera angle. including precoding desired settings. 5. fatal mistake that companies make when they perform a SMED event is that they believe that once the original event is over they ve completed their mission one and done as they say. Continual improvements requires. In addition. New technologies emerge. Internal setup can be reduced by simplifying or eliminating adjustments. In most cases. A Lean enterprise continually seeks to make improvements and is never satisfied with good enough . Today s best practice may not be tomorrow s. making movements easier etc. locating tools and dies near the points of use. and keeping machines and fixtures in good repair. 6. preventing misalignment. that you go back and keep working at reducing setup times. better setup procedure has been established. Perform setup activities in parallel or eliminate them entirely: Adding an extra person to the setup team can reduce time considerably. eliminating tools.