SMED PROJECT

To reduce the change over time for Draw tool, to

increase machine availability and horizontal deployment
to other machines.

Location – SBU-B Press Team Members –

shop Shital Bhosale
Roshan Marar
Aditya Satoskar
Atul Khemnar
 SMED
What is SMED ? Single Minute Exchange of Die, Shorter Set-up
Times, Achieving Change-over Operations under 10 minutes.
• How SMED Is Important ?
- Overcome Trouble with Large Lot Production
- Benefits of SMED for Companies – Variety of Products, High Quality,
Good Price & Speedy Delivery as determined by customer.
- Benefits of SMED for You – Supports Job Security by Strengthening
Competitiveness.
• Understanding Important Terms & Concepts
- Manufacturing Process
- Manufacturing Operations
- Setup Operations
 Importance of SMED
Why is it important for Companies ?
Customer needs are met –
• With Variety of Products,
• Ensuring Less/Elimination of Waste,
• Cost-effective Production &
• In Smaller Quantities.
 Rules of SMED
1. The time for changeover is the time taken from the last piece to the first good
piece of the next component.
2. Internal exchange is the activity that is performed inside the machine /equipment-
when the machine is stopped.
3. External exchange is the activity that is performed outside the machine
/equipment-when the machine is running
4. Set up time -is the time to keep all tools, fixtures, parts ready for the next
operation - this changeover time should be ZERO
5. Replacement time -is the time taken to change the fixture/die, cutting tools and
location/clamping of part for the next operation.
6. Adjustment time -is the time taken to set the tooling's and process including
inspection of first off component for acceptance
7. Avoid bolts and nuts Reduce amount of fastening and one turn fastening. One
touch clamping
8. Use block gauges for inspection
9. Use end stops for easy setting
10. Standardize fixture base plates and change only parts
 Steps to implement SMED
1. Collect data on changeover - ref Chart 1
2. Classify data into internal and external activity as per rule.
3. Move as much internal to external -first cut
4. Classify internal activities into parallel and sequential activities.
5. Classify the changeover activity as one of these: set up / replacement / adjustment-
ref Chart2
6. Prepare list of hand tools, tool holders, gauges / measuring instruments reqd.
7. Prepare the sequence in which it is required.
8. Layout as per sequence in a template.
9. Design and make a SMED trolley for keeping all reqd. (Step 6) items and reqd. Qty
part for and after machining
10. Keep all items in the trolley-check ease of grasping and closeness to point of use
11. Plan the changeover after ensuring set up time is zero, and as much internal is made
external, carry out parallel internal exchange operations simultaneously (on
replacement activity)
 Steps to implement SMED
12. Try out the changeover, and record time taken for changeover.
13. If time is less than 10 minutes, standardize the new sequence and method
14. If time is more than 10 minutes, standardize the method and consider
converting some internal activities to external.
15. Reduce time taken by the longest time consuming internal activities.
16. Eliminate adjustment time (try to get first piece right).
17. Continue improvement till SMED of < 10 min is achieved.
 SMED Project Details
• Part Family – Round Lock (RL)
• Part Name – Chassis Cover Threaded
• Process Name – 4th Draw
• Machine No. – W683
• Machine Type – Mech. SEW Press
• Operator Name – Vikas N.
• Current Time for Changeover – 39mins
• Target Changeover Time – under 10mins
 Initial Time Study Details
• Total Time required for change over = 39 mins (2366 secs)
• Total number of activities = 49
• Number of Internal activities = 49
• Number of External activities = 0
• Number of Set-up activities = 20
• Number of Replacement activities = 27
• Number of Adjustment activities = 2
SR
Action Plan for First Trial
No Activity Description
1 spanner collect from other machine
2 search and bring trolley from other machine
3 search for available space and keep tool in rack
4 searching for new die
5 search for liners
6 search for Allen key
7 remove shank from other die and fix to new die
8 knock out searching
9 searching for washer due to bolt not tightening
10 searching for spanner
11 check thread size of die for stud selection
12 searching for stud, stud plate, spring
13 adjust plate for spring, plate not match
14 Again searching for transfer plate
15 search for washer for transfer plate
16 waiting for supporting man power
17 transfer pin taken out from cotton pouch
18 bring die, liner and Allen key to machine
Action Plan
Standard Tool kit provide to each M/C
Trolley parking Position define & to be maintained
Define Tool position product family wise & with colour Coading & Identification
Define Tool position product family wise & with colour Coading & Identification
Define position for liners Identification with colour as per size & Index to rack
Standard Tool kit provide to each M/C
Provide Shank to each tool
Maintain knock out with each tool
Keep Washer into Standard Tool kit
Standard Tool kit provide to each M/C
Thread size of tool to be maintained on tag with tool
Define position for stud, plates spring Identification as per size & Index to rack
Define position for plates Identification as per size & Index to rack
Define position for plates Identification as per size & Index to rack
Keep Washer into Standard Tool kit
Tool setter will be available during setting
Can be done by helper
Die, Liner and Allen Key to be kept near machine before end of batch of previous
part
Action Plan to Reduce Time for Internal Activity
Sr. no Activity
1 ok reports received, and production start
2 tighten the clamping bolts in T-nut
3 increase the spring tension
4 checking spring tension while tightening
5 height checking with spanner for stroke length Operator training & std Scale provide for setting
and adjust ram height
6 stud tighten to die manually
7 transfer plate and spring tightening
8 loading die on machine and remove trolley
9 tighten bolt of sank holder with spanner
10 machine start, entry setting and one
component trial done. Component stuck
11 bolt tighten with spanner
12 machine start and remove old liner from
machine
Cycle time reduction Idea
Whenever gauges possible that should be provide on M/C
FPI to be start & run production once inspection complete
Activity can plan parallel two person can work on same &
Clamping Provision change
Wrong Spring uses so extra time goes & provide special
spanner to tight bolt
Wrong Spring uses so extra time goes & Operator tighten two
times lesser idea about tension required
Special spanner provide for bolt tightening & stud thread
damage required more time so use new one studs
Non std plate use to needs to adjust -Provide std plate so
easily fit
Provide addition support manpower for loading unloading
die
Pneumatic gun provide for screw tightening
Die setter used for toll setting has good skill
Pneumatic gun provide for screw tightening
One time old & New Tool with liner to be change from M/C -
training to operator
Action Plan to Reduce Time for Internal Activity
Sr. no Activity Cycle time reduction Idea
13 loosen die clamping bolt Pnematic gun provide for screw tightening

14 increase entry step-by-step to achieve Die setter used for toll setting has good skill
required dimension
15 machine start, ram up Die setter used for toll setting has good skill
16 loose the nut of shank holder Pnematic gun provide for screw tightening

17 remove locator plate and insert transfer pin Die setter used for toll setting has good skill
and put the locator plate back on tool
18 clamp support adjust wrt to the die bottom Pneumatic clamping provide for tool clamping
plate
19 initial die setting entry reduced for die Die setter used for toll setting has good skill
unclamping
20 load new liner on machine One time old & New Tool with liner to be change from M/C
-training to operator
21 machine start and ram up Die setter used for toll setting has good skill
22 remove the shank holder Die setter used for toll setting has good skill
23 unload tool on trolley One time old & New Tool with liner to be change from M/C
-training to operator
24 remove die and move in front to unload One time old & New Tool with liner to be change from M/C
-training to operator
 BEFORE PHOTOS

Cupboard for tool

No Space For SMED trolley 5S Not
Accessories Not
Movements of SMED maintained
maintained
trolley
 BEFORE PHOTOS

All Tools kept Mixed & No Space For Tool Tool Kit Box Not
Not Identified Movement Trolley Available at Place
at location
 First Trial Time Study

• Number of Internal activities moved to External activities = 2

• Total Time saved in these activities = 43secs
• Number of Non-essential External Activities to be eliminated = 16
• Total Time saved in these 16 activities = 11.5mins (690secs)
• Number of Non-essential Internal activity eliminated = 6
• Total Time saved in these 6 activities = 3.96mins (238secs)
• Total time saved in Essential Internal Activities in first trial =
5.5Mins(330 sec)
 First Trial Summary
• Time taken for tool changeover in initial trial= 39mins(2366 sec)
• Time taken for tool changeover in first trial after primary action =17.3
min(1038 sec)
• Time saved after primary action=21.7mins(1328 sec)

DATA
Thank You