I.4.

SMED
• What is SMED;
I. Production Flow • Target of SMED;
• Benefits of SMED;
5. Low Cost • The 5 steps of SMED;
Automation
• The Evolution of Setup Time;
4. SMED
• Step 1;

3. Standard • Step 2;
Work
• Step 3;
2. Border • Step 4;
of Line
• Step 5;
1. Layout and
Line Design • Standardization;
• SMED in Big Lines;
• Follow-up.

Movie: Movie:
Smed Old Smed AU

Movie: Movie: Movie:

Smed F1 Smed FB Smed Valeo

1
 What is SMED ?

S INGLE
M INUTE CHANGE OF DIE (Machine)
IN LESS THAN 10 MINUTES
E XCHANGE OF (original definition)
D IE

The SMED is a method, developed in the Toyota group by Shigeo Shingo, that is
used in the analysis and improvement of the time lost in changes of production series
(also called changeover time).

2
 Target of SMED

Reduce the total time of lost efficiency due to a product changeover

Efficiency

100%

80%

60%
Product “A” Product “B”
40%

20%

10%

0%

Machine stop
Time

Lost of efficiency

3
 Benefits of SMED

Allows to reduce
the stocks
Shorter series
becomes cheaper
(reduce batch size)
Allows to improve
Reduces the client service
SMED unproductive time (lead time, quantity)

Enlarges real
capacity of machines
Reduce CAPEX and
Production Costs

4
 The 5 Steps of SMED

Changeover in less than

Step
Step 56
SMED 10 minutes

Step 4
•Improvement of logistic support
Reduce external work •Improvement serviceability

Step 3 • Eliminate adjustments and settings

• Simplify fixation and tightening
Reduce internal work
• Parallel work

Step 2 • Pre-assembly
Convert internal work • Pre-adjustments
in external work • Pre-heating
Step 1
• Standardize Work to be done with the machine stopped
Standardize Internal Work • Work to be done after stopping
Starting
point Register and classify all the necessary working elements
• Video
Study of the actual situation • Chronograph

• Absence of method
Changeover method • Preparation time with big variations
not rationalised • There is no distinction between external work and internal work

Internal Work: Tasks which can only be done when the machine is not running
External work: Tasks which can take place when the machine is running (before or after)

5
 The Evolution of Setup Time

Equipment stopped

Initial
situation ????
Step 1
I E I I E I I I E I E E I

Step 2
E E I I I I I I I I E E E

Step 3 E E E E I I I I I I E E E

Step 4 E E E E I I I I I E E E

Step 5 E E E I I I I I E E
Working Stopped Working
External Work Exchange of the die External Work
before the change After the change

Internal work: can only be done with the machine stopped

External Work: can happen with the machine working

6
 Step 1: Study of the Actual Situation

75 25

50

# Operação Tempo Acumul. InternaExterna Categ .

1 Buscar o guincho e o carro 43 43 x T
2 Abrir protecções da máquina 15 58 x
3 Fechar máquina (em manual) 6 64 x
4 Buscar ferramenta 32 96 x T
5 Desapertar fixações 127 223 x AP
6 Fixar o cortante com o guincho 8 231 x
7 Abrir máquina (em manual) 3 234 x
8 Retirar o cortante para o carro 12 246 x M
9 Levar o cortante ao armazém 62 308 x T Categorias:
10 Trazer o novo cortante 57 365 x T T - Transporte
11 Fixar guincho 9 374 x AP - Aperto
12 Colocar cortante na máquina 16 390 x M AF - Afinação
13 Fechar máquina (em manual) 6 396 x M - Montagem
14 Apertar fixações 133 529 x AP O - Outros
15 Levar carro e guincho embora 40 569 x T
16 Arrumar ferramenta 25 594 x T
17 Afinar máquina 155 749 x AF
18 Fechar protecções da máquina 16 765 x M
Total 765

• Film (video) all the preparation work

• Timekeeping the different tasks
• Copy the data to a form
• Classify the tasks in internal or external
• Classify the tasks in different categories
• Identify waste
• Calculate the total and sub totals time by category

7
 Step 1: Study of the Actual Situation

75 25

Método actual de mudança de cortante em prensa hidráulica 50

# Operação Tempo Acumul . Interna Externa Categ .

1 Buscar o guincho e o carro 43 43 x T
2 Abrir protecções da máquina 15 58 x
3 Fechar máquina (em manual) 6 64 x
4 Buscar ferramenta 32 96 x T
5 Desapertar fixações 127 223 x AP
6 Fixar o cortante com o guincho 8 231 x
7 Abrir máquina (em manual) 3 234 x
8 Retirar o cortante para o carro 12 246 x M
9 Levar o cortante ao armazém 62 308 x T Categorias:
10 Trazer o novo cortante 57 365 x T T - Transporte
11 Fixar guincho 9 374 x AP - Aperto
12 Colocar cortante na máquina 16 390 x M AF - Afinação
13 Fechar máquina (em manual) 6 396 x M - Montagem
14 Apertar fixações 133 529 x AP O - Outros
15 Levar carro e guincho embora 40 569 x T
16 Arrumar ferramenta 25 594 x T
17 Afinar máquina 155 749 x AF
18 Fechar protecções da máquina 16 765 x M
Total 765

8
 Step 2: Separate Internal Work from External Work

Example: Checklist of materials preparation

NECESSARY MATERIALS TO EXCHANGE OF DIE

Tick all the necessary material

Tools : Accessories:
 Chave de luneta 20  Êmbolo
 Chave Unbrako 16  Haste
 Chave de bocas 18  Contentor
 Posicionador

Mould: Transportation supports:

 Molde  Diferencial
 Mangueiras  Carro de transporte
 Olhais 
Corrente suspensão
 Cabo eléctrico

9
Step 3: Convert the Internal Work into External Work

Before After

Spring

Die Die

10
 Step 4: Reduce (eliminate) Internal Work

Die Stopper

Roller

Pushing in

11
 Step 5: Reduce (eliminate) External Work

X 23 Z 12 AB 45 L 07

X 23 Z 12 AB 45 L 07

ZZ 33 K 67 A 88

A 88
ZZ 33 K 67

G 55 M 15

40 50 60 70 80
G 55
M 15

12
 Standardisation

Standard procedures of the preparation work

Standard procedure of the die changeover

Máquina: Prensa 50 ton Mudança de Refª: X4702 para Refª: Z5234

Operador Ajudante

Operação Tempo Ferramenta Operação Tempo Ferramenta

Trazer novo cortante 30 Carro
Preparar guincho 9
Preparar ferramenta 5
Pára a máquina e fecha-a 5
Retira protecções 4 Retira protecções 4
Desaperta fixações 20 Chave 18 Desaperta fixações 20 Chave 18
Abre máquina (em manual) 3 Pega no guincho 2
Fixa o guincho ao cortante 4
Pega em material de limpeza 3 Retira cortante 12
Limpa pratos da máquina 6 Fixa guincho ao novo cortante 4
Arruma material de limpeza 3 Coloca novo cortante 12
Fecha máquina (em manual) 4 Retira guincho 3
Aperta fixações 20 Chave 18 Aperta fixações 20 Chave 18
Programa a máquina 43 Coloca protecções 10
Faz o arranque da máquina 3 Leva cortante anterior 30
Arruma ferramenta 12 Carro
Tempo de paragem 114

13
 SMED in Big Lines

Workers
involved

Set up Ajustar
Worker A Feeder Carregarmatéria-prima
Transportadores

Worker B Set up Ajustar

Set up Press
Feeder Transportadores

critical
Substituir way
AssistantC Carregarmatéria prima
calibres

Set up Press Setup

Fitter D Setup Embaladora
Paletizadora

0 10 20 30 40 50 60 70 80
Time (minutes)

14
 Follow-up

Follow the trends of the setup time and check the effect
of improvement actions (updating the changeover indicator).

Evolution of setup time

Preparation
time

Target

Evolution

= effect of improvement actions

Actions S 23 S 24 S 25 S 26 S 27 S 28 S 29 S 30 S 31 S 32 weeks
Sep. internal and external work
Pre assembly
Standardize tools
Simplify adjustments
Parallel work

15