SMED and TPM
1
DIES (MOLDS)
2
ORIGIN OF SMED
Shigeo Shingo introduced Single-Minute
Exchange of Dies (SMED) after 19 years of
observing setup operations in factories.
The objective is to reduce setup time.
Setup time is calculated as duration between
the completion of last good piece of product
A and the time the first good piece of product
B is completed.
This includes the time to change materials,
tools, fixtures, and dies, and to stabilize the
process again to make good parts.
3
Running Product A Running Product B
First Good
Last Good
Product
Product
First Good Product
Last Good Product
Running Product A Running Product B
4
Shingo discovered two main points:
Point 1: Setup operations can be divided
into two categories:
Internal setups: which are performed while
the machine is not operating. An example is
changing the tooling in the machine.
External setups: which are performed while
the machine is running. An example of this
is setting tools for a different product.
Point2: Converting internal setups to
external setups can substantially reduce 5
changeover times.
BENEFITS OF SMED
Error reduction: Chance for error is reduced
because of fewer physical adjustments in process
changes
Flexibility in scheduling is increased because
setup is decreased.
Reduction in large-scale defects: By producing
smaller runs, there is a decreased chance of a large-
scale defect.
Customer service is improved because of the
ability to changeover quickly and meet changing
customer needs.
Increase in uptime: Faster changeovers increase
productivity by reducing the amount of downtime.
6
Higher safety: By simplifying setups, the risk of
injury is reduced.
7
STAGES OF SMED
Step 2: Separate
Step 1: Document
internal and external
current process
setup
Step 3: Converting
internal setup to
external setup
Step 4: Streamlining Step 5: Document 8
the setup operation new setup
STEP 1: DOCUMENT CURRENT
OPERATION
Select the setup operation to be analyzed.
Observe the setup by using video capture
techniques for easy reference.
Show the video to the setup person and
others involved.
Using the video, record the time and motion
on a setup analysis chart.
Chart each time category in Pareto format.
Time categories include searching, fixture
change, walk time, first piece inspection,
gauging, tool change, and programming.
9
STEP 2: SEPARATE INTERNAL AND
EXTERNAL SETUP
You must separate internal and external elements to
identify areas for improvement. The goal of SMED is
to have all the necessary tools at the station so the
operator never leaves to perform any of the external
setups.
Internal activities are performed while the machine
is not operating. External elements are performed
while the machine is running.
Operators can easily perform several tasks while the
machines are running. For example calling proper
personnel, setting tools, and getting parts. However,
many operators do not begin these tasks until the
machine stops.
10
Setup time can be reduced by 30%–50% if internal
setup can be moved to external setup.
STEP 3: CONVERT INTERNAL SETUP
TO EXTERNAL SETUP
Find out which internal setups can be converted to
external setups with minor changes.
Three techniques help to convert internal into external
setup:
Prepare the operation conditions in advance: It means having
the parts, tools, and conditions ready before starting the
internal setup. For instance preheat die molds in advance
instead of heating the molds after setup.
Standardize essential functions: To minimize adjustments,
use standard tools from one product to another.
Use intermediary jigs: An intermediary jig is a jig that is
designed to hold another jig that can be quickly changed.
Intermediary jigs are standard plates or frames that can be
removed from the machinery. The purpose is to externalize
the setup as much as possible. The current fixture is attached
to an intermediary jig on the machine. The next fixture is also 11
installed onto an intermediary jig as an external setup.
12
STEP 4: STREAMLINE THE SETUP
OPERATION
Streamline your external setup
Apply 5S
Organize your materials
Tools should be visible and easy to retrieve
Streamline your internal setup
Implementing parallel operations: By dividing setup
operations between two people, one for each side
of machine, this eliminates the walk time and
reduces internal setup time.
Using functional clamps: Bolts are enemy of SMED
as they slow down internal setups. Bolts often get
lost, get mismatched, and take too long to tighten.
Functional clamps attach items in place with a
13
minimal amount of effort and can be loosened or
tightened quickly.
STEP 5: DOCUMENT THE NEW SETUP
Document the new setup.
Video tape the new setup.
If new systems are installed, then provide
training.
14
TOTAL PRODUCTIVE MAINTENANCE
(TPM)
There are two types of maintenance:
Breakdown maintenance: Maintenance of equipment
when it breaks. This type of maintenance is
considered waste in LEAN.
Preventive maintenance: Maintenance of equipment
at regular time intervals.
Traditionally, the whole responsibility of
maintenance falls under the maintenance
department.
TPM is an innovative approach to equipment
maintenance involving maintenance personnel
and operators working in teams focusing on
eliminating equipment breakdowns and 15
equipment-related defects.
PHASES OF TPM
16
17
OVERALL EQUIPMENT EFFECTIVENESS
(OEE)
Measure of the percent of time a piece of
equipment is producing quality product.
OEE measures the effect of six big losses,
which include breakdowns, setup, idling,
minor stoppages, quality factors, and rework.
18
OEE CALCULATION
( )
19
EXAMPLE (OEE IN A WEEK)
20
