( One Step Setup) Set-up and changeover reductions for equipment, tooling and machines. A STRATEGY FOR PERFORMANCE EXCELLENCE 2000,, LLC, all rights reserved 1 Performance Excellence Series Training Module Elements Executive Overview Lecture notes Knowledge Breakthrough Tools Workbook Lecture notes Participant manual 2000,, LLC, all rights reserved

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 2000,, LLC, all rights reserved 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. 2000,, LLC, all rights reserved 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 ! 2000,, LLC, all rights reserved

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 2000,, LLC, all rights reserved 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. 2000,, LLC, all rights reserved 7 Tool Kit Comparison Major Tools Cp/Cpk DOE SPC FMEA Regression Process Map 5 whys /2 hows Pareto Fishbone CPI (6) Kaizen Lean

Description 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 Elimination waste Visual Mgmt Poka-Yoke Spaghetti Chart

Kanban Takt Time Std Work SMED TPM Cellular Flow 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 2000,, LLC, all rights reserved 8 Identify what types of internal and external setup times are involved in the following pictures. Picture A: Wire Cutting Machine 2000,, LLC, all rights reserved

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) ___________________________ ___________________________ ___________________________ ___________________________ ___________________________ ___________________________ ___________________________ ___________________________ 2000,, LLC, all rights reserved 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? ____________________________________________________ ____________________________________________________ 2000,, LLC, all rights reserved 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. 2000,, LLC, all rights reserved 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. 2000,, LLC, all rights reserved 13 TraditionalSetup Resource Consumption Analysis Setup Steps Setup Type Traditional Internal Setup Type Resource Setup Type Setup Type

Traditional Consumption One-Step One-Step External Internal External ( %) Preparation X 20 % X 5% X 15 % X 50 % X

10 % X Mounting & Extraction Establish Control Settings X X First Run Capability N/A N/A Process Improvement 2000,, LLC, all rights reserved X 14 Think Break

Examples of wastes in a traditional setup ! What kind of setup wastes can you identify in this pictures ? ________________________________________________________ ________________________________________________________ ________________________________________________________ 2000,, LLC, all rights reserved 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 2000,, LLC, all rights reserved 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. 2000,, LLC, all rights reserved 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 2000,, LLC, all rights reserved 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. 2000,, LLC, all rights reserved This clamp attachment requires one step to attach the die to a machine.

19 SMED for the Workplace Training and Sourcebook for SMED Worksheets How to Use This Manual The continuous improvement tools that are presented in Sections 1-10 of this manual are shown in order of use. These forms MUST be completed in the order presented in this manual. Each section contains a brief description of the tool, its purpose, when to use it, who should use it, how to use it, and the expected results. Remember to focus on the elimination of waste. Strive to maximize yields and obtain cost reductions from existing machinery and equipment before buying solutions. Improve current systems and techniques before automation. Automating a system or practices without first having an understanding of the process will not solve underlying process problems. Perhaps the most important point to remember is that

we must understand a process before we make any attempt in changing it. No Tampering is the first rule of continuous improvement. We can not tamper with a process without understanding it. By using these tools, we will all share a common and systematic approach for questioning, analyzing, proposing solutions, experimenting, and finally, implementing proven changes. The problems that exist in the world today cannot be solved by the same level of thinking that created them. M easurem ent Im provem ent SM ED Tem plate Identifyw

aste Table of Contents Section 1 Section 2 Section 3 Section 4 Section 5 Section 6 Development of SMED To Do Plan: Establishment of the SMED teams Action plan identifying the specific actions required for each of the four (4) phases of SMED implementation. Deliverable includes action plan and associated tasks with the SMED implementation. 4 Waste Identification Map: Identification of the 9 wastes associated with production of products and services. A detailed map of each major work area is developed describing the major types of wastes in each area. These wastes are the improvement opportunities that exist prior to SMED. The overall wastes is calculated for all the work areas and identified on the 9 Waste Radar

Chart 7 SMED Action sheet: Establishing baseline key performance metrics in terms of key deliverables, photographs, and current conditions of the before SMED implementation phase. Deliverable includes the SMED action sheet. Please note: A video recording of the before setup operation is recommended. 11 Setup Process Map: A map showing the critical setup inputs, processes and outputs for each machine/equipment setup operation. Standard Operation Setup Check-sheet: Identifies the setup operations and respective process parameters required for an effective changeover. Also identifies resource requirements for the setup operations previously identified. Setup Work Combination Sheet: Used to graphically display the amount on Internal and External setup time within a changeover process for a particular machine. It further shows tasks that are performed in series and parallel for further analysis. 14 17 21 Section 7

Section 8 Section 9 Section 10 Section 11 Section 12 Setup Conversion Matrix: A matrix identifying the methodology for converting internal setup operations into external setup operations. SMED Conversion To Do: An action list identifying specific setup improvement tasks for each conversion opportunity identified in the Setup Conversion Matrix. Operational Control Plan: Procedure for setup operations AFTER setup improvements have been made. This is a control plan to ensure consistent setup with the newly identified setup parameters as a result of the SMED implementation. Includes visuals of setup tooling, & supplies. Standard Visual Sign: Used to identify the machine, tooling, supplies, & inventory location within the workplace. Shows the type of item, location of item, quantity of item, and the preceding and following processes. SMED Status Report: Provides a format to compare improvement efforts between a desired target and known starting value. 24 27 30

34 36 Waste Identification Map: Identification of the 9 wastes associated with production of products and services. A detailed map of each major work area is developed describing the major types of wastes in each area. These wastes are the improvement opportunities that exist prior to SMED. 9 Wastes Radar Chart: After the completion of SMED, the results of the waste reduction is recorded, charted and compared to the initial 9 Waste Radar Chart. 39 Section 7 Setup Conversion Matrix SET-UP CONVERSION MATRIX Sheet Date: Page of Area/Department NO. Machine/Equipment Name

CURRENT PROCESS Task/Operation Set-up Tools Required CURRENT TIME Internal External Operator Number Standard Set-up Time Date Prepared Minutes IMPROVEMENT Current Total: PROPOSED TIME Internal Improve Total

Conversation Methology Preparation of Set-up Process Combining Equipment Functionality Standardized Jigs External Setup Conversion Matrix Purpose Used to identify specific actions taken to convert internal setup operations into external setup operations as part of Phase 1 in the SMED program. When To Use The Setup conversion Matrix should be used after the Setup work Combination sheet has been completed. Who Should Use It The Setup conversion Matrix can be used by anyone involved in area or process improvement. Expected Benefits

The resultant deliverables will be specific actions aligned with each of the three conversion methodologies(Preparation of Setup Processes, Combining Equipment Functionality, Standardized Jigs) to convert internal setup operations into external setup operations. How To Use It 1. Complete the sections titled Area/Department, Machine/Equipment Name, Setup Tools required, Operator Number, Date, and Standard Setup time. 2. List all the specific setup tasks/steps in sequential order(can obtain this information from the process map)under the column titled tasks/operations and indication the step number under the column titled No.. 3. Next list the total amount of Internal and External Setup time in the appropriate column for each task Before any changes have been made. 4. Complete the column titled improvement by listing the specific continual improvement actions that will be taken to convert the Internal setup time into External setup time. 5. Next complete the column titled proposed time by listing the expected Internal and External setup times. 6. Finally add up the total internal and External setup times for both the current and proposed columns and list these at the bottom of the form in the sections titled Current Total & Improved Total respectively.

Next Step You are now ready to move to the next step, the SMED Conversion To Do List.

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