In article No. 74 of June 26, 2023, I had superficially mentioned the SMED acronym for (Single Minute Exchange of Die). With this post, I would like to add details to what I have already written, of course you will find some repetition, but also many additions that I hope will benefit you.

Implementing the SMED method requires strategic planning and in-depth analysis of setup processes.

Here are the basic steps for successful implementation of SMED:

1.Analysis of setup times:

• It is important to accurately measure and record setup times for each step in the process. This can be done with stopwatches, video recordings, or digital monitoring systems. Analysis allows critical activities to be identified and separates internal from external activities.

2.Observation and Analysis of the Setup Process 🔍

• Begin with direct observation of the equipment change process.
• Record each step, the time required and the movements needed.
• The goal is to understand how the changeover is performed, highlighting downtime and inefficiencies.

3.Separation between Internal and External Operations 🔄

• Internal Operations: Activities that can only be done while the machine is stopped.
• External Operations: Activities that can be done while the machine is running.
• Transfer as many internal operations as possible externally to reduce the actual downtime of the machine.

4.Conversion of Internal to External Operations 🔁

• Convert internal operations to external as far as possible.
• For example, prepares equipment, tools, and materials while the machine is still operational.
• This conversion may require structural changes or the implementation of new tools, but it leads to great time savings.

5.Rationalization of Remaining Operations ✂️

• Analyze each remaining task to simplify, eliminate or reduce its time.
• It could mean reducing the number of screws to be unscrewed, streamlining technician movements, or improving tool accessibility.

6.Documentation and Standardization of the Process 📄

• Create standard and detailed procedures for each step of the optimized setup.
• Provide clear instructions and visual support tools (checklists, diagrams, etc.) to guide operators.
• Standardize allows for consistent results each time equipment change is needed.

7.Rapid equipment and tools:

• Replacing heavy or complex equipment often requires the use of lifting tools or quick-release mechanisms. The use of equipment designed for quick changeover, such as quick-release systems, can reduce setup time.

8.Visual Checks and Poka-Yoke

• (Visual check systems (e.g., colored labels or indicators) and Poka-Yoke devices (error-prevention systems) reduce errors and speed the correct placement of tools and equipment.

9.Team Training and Engagement 👥

• a.Train operators on optimized setup standards and SMED logic.
• b.Involve the team in seeking continuous improvements: operators, knowing the process well, can provide valuable feedback and suggestions to further reduce time

10.Monitoring and Continuous Improvement 📊

• Constantly monitor setup times to see if the goal has been achieved.
• Adopts a continuous improvement (kaizen) approach to further optimize the process and maintain results over time.

By implementing the steps listed above, significant reductions in setup time and increased productivity can be achieved. The SMED approach not only improves efficiency, but also makes the work environment more organized and the team more engaged.

Implementing SMED takes time and effort, but the results speak for themselves. It is a methodology I recommend to anyone who works in manufacturing and wants to make a real leap forward

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