( One Step Setup) Set-up and changeover reductions for equipment, tooling and machines. A STRATEGY FOR PERFORMANCE EXCELLENCE 1 Performance Excellence Series Training Module Elements Executive Overview Lecture notes Knowledge Breakthrough

Tools Workbook Lecture notes Participant manual 2 Table of Contents Knowledge Breakthrough Session 1.0 Introduction....... 4 Session 2.0 Waste Management . 12 Session 3.0 Setup Practices.. 22 Session 4.0 Traditional /Strategic Setup Approach 29 Session 5.0 SMED Implementation Planning. 34 Element 5.1 Implementation Team 36 Element 5.2

Implementation Plan. 37 Element 5.3 Communication Plan. 38 Element 5.4 Training Plan. 40 Element 5.5 One Step Setup.. 42 Element 5.5.1 Separate Internal from External Setup 44

Element 5.5.2 Integrating Internal into External Setup. 49 Element 5.5.3 Reducing Setup Processing Time. 63 Element 5.5.4 Optimizing Setup Processes.. 92 Element 5.6 Verification & Standardization 95 Session 6.0 Summary 105 3

SMED is Continuous Improvement It is a customer driven requirement. Customers are demanding: Product and service diversity Lower costs Higher reliability and quality. In essence organizations need to become leaner ! So organizations must: Produce smaller lots, more frequently. Expand the scope and diversity of products and services. Reduce quality defects. 4 Ultimately, SMED focuses on reducing changeover and set-up times, thus enabling organizations to: Produce smaller lots of products and services more frequently !

Develop a broader scope of products and services ! Reduce quality defects towards zero ! Meet Customers Expectations ! 5 What Does Set-up/changeover reduction mean for my business? Increased customer service levels and profits ! Via Waste Elimination resulting in: Reduced Lead Times-Faster Delivery Zero Inventories-Reduced Working Capital Improved Quality Improved Safety Smaller lots of products-flexibility Diversified Product & Service Options 6

Why SMED ? Look Familiar ? To eliminate the wastes that result from uncontrolled processes increasing inventories and lead times.. To gain control on equipment, material & inventory. Apply Control Techniques to Eliminate Erosion of Improvements. Standardize Improvements for Maintenance of Critical Set-up Parameters. 7 Tool Kit Comparison Major Tools

Cp/Cpk DOE SPC FMEA Regression Process Map 5 whys /2 hows Pareto Fishbone CPI (6) Kaizen Lean Process capability assessment Design of experiments Process control based on statistics and data analysis

Risk assessment tool Correlate effect one variable has on another Map process steps to communicate and identify opportunities Determination methods for root cause discovery Column chart ranking items highest to lowest Cause / Effect Diagram 5S Visual Mgmt Poka-Yoke Spaghetti Chart Kanban

Takt Time Std Work SMED TPM Cellular Flow Description Elimination waste Emphasis on visual techniques to manage process Error proofing techniques

Material storage technique used to control process Determine pace or beat of a process Evaluate tasks done during a process Single minute exchange of dies - Quick machine set up Integrate maintenance strategy with process Reduce inventory & cycle time through process layout and pull production techniques Expand ExpandProcess

ProcessImprovement ImprovementProgram ProgramtotoUtilize UtilizeKaizen KaizenTool ToolKit Kit 8 Identify what types of internal and external setup times are involved in the following pictures. Picture A: Wire Cutting Machine Picture B: Metal Stamping Machine 9 Identify what types of internal and external setup & times are involved in the

following pictures. Picture A: Wire Cutting Machine Picture B: Metal Stamping Machine Think Break Setup Type Time ( Min) ___________________________ ___________________________ ___________________________ ___________________________ ___________________________ ___________________________ ___________________________ ___________________________ Setup Type Time ( Min)

____________________________ ____________________________ ____________________________ ____________________________ ____________________________ ____________________________ ____________________________ ____________________________ 10 Think Break Internal External Setup Classify Three items under each item category. Internal External

____________ ____________ ____________ ____________ ____________ ____________ Which items would you convert from internal to external Setup ? ____________________________________________________ ____________________________________________________ Why? ____________________________________________________ ____________________________________________________ 11 Traditional Setup Practices Material movement occurs after the machine is

turned off. Completed products are transferred to next operation. Raw material is moved after the machine is stopped. Detection of defects or missing equipment is noticed which the machine is running. Setup tooling delivered after the changeover has begun. Defective product identified after internal setup has begun. Defective tooling,fixtures, setup instruments are noticed after the machine is

turned on. The operator notices that equipment is missing after internal setup has begun. 12 5 TraditionalSetup Steps Defined Preparation - Ensures that all the tools are working properly and are in

the right location. Mounting & Extraction - Involves the removal of the tooling after the production lot is completed and the placement of the new tooling before the next production lot. Establishing Control Settings - Setting all the process control settings prior to the production run. Inclusive of calibrations and measurements needed to make the machine, tooling operate effectively. First Run Capability - This includes the necessary adjustments( recalibrations, additional measurements) required after the first trial pieces are produced. Setup Improvement- The time after processing during which the tooling, machinery is cleaned, identified, and tested for functionality prior to storage. 13 TraditionalSetup Resource Consumption Analysis Setup StepsSetup Type

Traditional InternalSetup Type Traditional ExternalResourceConsumpt 14 Think Break Examples of wastes in a traditional setup ! What kind of setup wastes can you identify in this pictures ? ________________________________________________________ ________________________________________________________ ________________________________________________________ 15

One Step Setup Implementation Plan Step 1 Step 2 Step 3 Step 4 Step 5 Develop One Step Setup Develop Specific Develop Communication

Develop One Step Implement One Step Implementation Team Implementation Plan Plan Setup Training Plan Set-up Separate Internal from External Progressive

Setup Enhancements Reduction of Setup Processes Optimizing Setup Processes Integrate Internal into External Setup Step 6 Verification / Standardization 16 Phase 2

Combining equipment functionality Involves standardizing the equipment ( parts, tooling, processes) based on commonality between setups to reduce the number of setup steps and cycle times. The common setup parts were identified and By using these fixtures, the parts are automatically centered and adjusted for height and flatness as a part of External setupnot Internal setup.

replaced with this jig/holder combination. Notice how different quantities of the same part can be setup with the same fixture. Also, these setups can occur while the machine is running. 17 Waste associated with finding, replacing, motion will be eliminated by this example of visual placement. Tooling supplies are clearly labeled

Tooling supplies are neatly assigned a unique location. 18 Phase 3: Reducing setup processing time. Elimination of Bolts & Adjustments. Example of One Step Fastening Bolt attachments requires 32 complete turns for each bolt or screw (1 for each thread) to fasten this bolt and die to a machine. This clamp attachment requires one

step to attach the die to a machine. 19 SMED for the Workplace Tr How to Use This ManualThe continuous improvement tools that are presented in Sections 1-10 of this manual are shown in order of use. ImprovementIdentify wasteMeasurementSMEDTemplate Thes Table of Contents Section 1Development of SMED To Do Plan:Establishment of the SMED teams Action plan identifying th Section 7Setup Conversion Matrix: A matrix identifying the methodology for converting internalsetup operations into external setup operation Setup Conversion Matrix

Section 7 SET-UPCONVERSION MATRIX SheetDate:PageofOperatorNumberStandard Set-up TimeArea/DepartmentMachine/Equipment NameSet- Setup Conversion MatrixPurposeUsed to identify specific actions taken to convert internal setup operationsinto e How To Use It 1. Complete the sections titled Area/Department,Machine/Equipment Name, Setup Tools required, Operator Nu

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