Looking for the most efficient production process for your organization? The SMED method helps you discover and implement this by reducing changeover times and increasing productivity. In this blog, we explain what the SMED method entails and how you can use it to shorten changeover times.
What is SMED?
SMED, which stands for Single-Minute Exchange of Die, is a method designed to ensure that a production process can be changed over quickly and efficiently. As part of Lean Manufacturing, this method is also referred to as Lean SMED. The SMED method asserts that each changeover should take less than ten minutes. These changeovers include all activities necessary to switch from a current production order to a new one. The SMED method originates from a concept by Shigeo Shingo, a key developer of the Toyota Production System. The goal was – and remains – to shorten changeover times so that more production time can be utilized.
What are the benefits of the SMED method?
Lean SMED leads to various benefits, including reducing changeover times and increasing production time. Additionally, the flexible and efficient production lines created by the SMED method offer organizations more opportunities. Thanks to these benefits, you can work towards reducing downtime, lowering costs, increasing productivity, and improving production planning. This results in a faster response time to customer demands, increased equipment reliability (thanks to the standardization of procedures), and the promotion of a culture of continuous improvement. All these advantages contribute to a production environment that operates responsively and cost-consciously.
What are the steps of Single-Minute Exchange of Die?
The Single-Minute Exchange of Die method works with seven basic steps, with the first six steps leading to the final step: continuous improvement. Below, we explain each step:
- Observation of the current changeover time: Document the entire process and measure the current changeover time. Identify bottlenecks in the process so they can be prioritized.
- Separation of internal and external setup activities: Identify which tasks can be performed while the machine is running (external tasks) and which can only be done when the machine is stopped (internal tasks).
- Conversion of internal to external setup activities: Perform as many tasks as possible while the machine is running to save time.
- Streamlining internal activities: Simplify and standardize tasks that are performed during downtime.
- Streamlining external activities: Optimize tasks that can take place during production.
- Documentation and standardization: Record the new procedures and ensure consistency.
- Continuous improvement: Regularly evaluate and seek further optimizations until all changeover times are reduced to less than ten minutes.
Example of a SMED project
Suppose a factory faces long changeover times between production runs and initiates a SMED project to observe the current process. The first step is to distinguish between internal and external activities, such as changing cartridges (internal) and preparing tools (external). The changeover time can be reduced by standardizing various bolt sizes to just one size, thus requiring only a size 13 wrench. Pre-setting all tools also saves time. By documenting procedures and scheduling regular training and feedback sessions, the changeover time is eventually reduced from ninety minutes to fifteen minutes. The SMED project can then be restarted to achieve a maximum changeover time of ten minutes.
OTED
Have you successfully completed a SMED project? Then you can take it a step further by implementing an OTED project. OTED (One-Touch Exchange of Die) aims to reduce changeover times to a maximum of one hundred seconds instead of ten minutes. To achieve this, only one action should be required to complete the changeover. This can make production processes even more flexible, efficient, and cost-effective.
Reduce your changeover time and optimize processes with EZ-GO
Digitalization and standardization are two aspects needed to optimize processes and reduce changeover times. EZ-GO is precisely focused on these two aspects. Checklists provide a visual conversion with clear photos and videos, guiding employees step-by-step through the procedure. With these standardized work instructions and checklists offered through a digital platform, all employees can maintain the same standard. This ensures clarity. Additionally, visual instructions and checklists help in working efficiently and reducing errors. With EZ-GO, implementing Lean SMED becomes much simpler, as real-time data collection and analysis can focus on smooth problem-solving and continuous improvement. Want to see how this works firsthand? You are welcome for a demo!