Quick Change Over
Monday, August 13, 2018
History Of SMED
Monday, August 13, 2018
Lean Tools
Monday, August 13, 2018
Traditional Vs SMED
Monday, August 13, 2018
Traditional Vs SMED
Driver’s
Motor
Traditional
Speedway
roadside
Car positioning ▪ Poor ▪ Quickly put in ideal spot
Assistance ▪ None ▪ Coordinated team
Capability ▪ Drivers not well prepared/ ▪ Pit crew is well trained and
trained practices often
▪ Hard to locate/position ▪ In place before the pit stop
Tire jack ▪ Manually operated, slow to ▪ Automatic and high speed;
raise car raises car almost instantly
Wheel nuts ▪ Hard to remove, requiring ▪ Removed/replaced by high-
many turns speed air tools in less than a
second
Time/ ▪ Not tracked ▪ Tracked religiously
performance ▪ Only concern – complete the ▪ Crews graded for
job speed/accuracy
Total time Hours Seconds
Monday, August 13, 2018
SMED Vs OTED
Monday, August 13, 2018
CHANGEOVER TIME
What is the correct method of measuring changeover time?
▪ Changeover time should be recorded as the interval between the stopping and full-speed
restart of operations – normally between the last good part produced in a production run
and the first good part produced in the next production run
Changeover time
Time = 0
minutes
Discrete manufacturing
Last First
GOOD GOOD
piece piece
Maintenance
Start of End of
PM or PM or
shutdow shutdow
n n
Monday, August 13, 2018
SMED STEPS
1. Observe the process
2. Spilt the activities into small elements
SMED
3. Separate it as internal and external Starts
&
Ends With 5S
4. Convert internal into external
5. Reduce the internal
6. Reduce the external
7. Reduce the adjustments
Monday, August 13, 2018
Internal & External
Internal steps External steps
Activities occurring during the Activities that could be performed
changeover that can only be while the equipment is running
performed when the equipment is
shut down
This stage is the critical
driver for Quick
Changeover improvements
– a high percentage of
operations are usually Machine is
external steps that could be operating
done before or after the
changeover process
▪ Remove dies ▪ Cleanup
▪ Change blades or tooling ▪ Tool preparation and retrieval
▪ Loosening/tightening critical bolts ▪ Assemble subcomponents
▪ Paperwork
Monday, August 13, 2018
How to convert External in to Internal
Monday, August 13, 2018
How to convert External in to Internal
Changeover time
Time =
0
Before External Internal External
After Externa Internal Externa
l l
Any activity that can be
performed safely when the
equipment is running, should be
converted to an external activity
Monday, August 13, 2018
How to convert External in to Internal
convert internal to external (continued)
Stage tools in Stage parts at Wait until the
the area the machines changeover is
before the prior to complete to fill
changeover to beginning the out paperwork
eliminate changeover
retrieval
during the
process
Monday, August 13, 2018
How to convert External in to Internal
Monday, August 13, 2018
SMED Carts
Monday, August 13, 2018
SET-UP Die Carts
Monday, August 13, 2018
USING SMED- Quick changeover
External
Internal
Job start Job end
Steps 0 Machine downtime 60
A Measure total job time 60
B Separate internal and external tasks;
perform external ones while 30 30
equipment is running
C Convert internal tasks into external 40 20
ones wherever possible
D Eliminate internal waste 40 10
E Eliminate external waste 20 10
F Standardize and maintain best 20 10
practice
Monday, August 13, 2018
World Class Challenge
Monday, August 13, 2018
How to convert External in to Internal (Case Study)
Monday, August 13, 2018
How to convert External in to Internal
What is Shoulder Cushion in Tyre ?
Shoulder Cushion
Shoulder Cushions are small,
sometimes contoured strips
of rubber placed on the body
ply, under the belt ends.
They help maintain a smooth
belt contour and insulate the
body plies from the belt
edges.
Monday, August 13, 2018
How to convert External in to Internal
CROSS FUNCTIONAL TEAM Team Leader Manufacturing
Manufacturing
Team Member Technology
Team Member Engineering
Team Member Production
Monday, August 13, 2018
How to convert External in to Internal
TARGET
[Link] Activity Resp.
Dec-XX Jan-XX Feb-XX
Time Study -
1 Team
Current Situation
Classification of
2
Activities
Kaizen Idea
3
Generation
Kaizen
4
Implementation
Observing the
7
Result
Standardization &
8
Monitoring
- Plan
- Actual
Monday, August 13, 2018
How to convert External in to Internal
➢ Loss Analysis
➢ECRS Technique
➢WHY-WHY Analysis
Monday, August 13, 2018
How to convert External in to Internal
Monday, August 13, 2018
How to convert External in to Internal
Monday, August 13, 2018
How to convert External in to Internal
Shoulder Cushion Setting Time was 240 secs
WHY ?
16 activities involved
WHY ?
Root Cause: Multiple settings are involved
Idea: Reduce Multiple Settings
Through E- C - R - S Techniques
Monday, August 13, 2018
ECRS
Activities Int. Ext. E C R S
Liner Windoff g
Unplugging the Brake Hose g g
Unlocking the cartridge & pulling the cartridge out g g
Raising the lever Opening the chuck & lowering the reel g g
Removing the empty reel g g g
Removing square shaft & inserting into new reel g g
Inserting the new reel into cartridge g g g
Positioning the reel shaft over the chuck g g
Locking the chuck g g
Closing the Lever & Lifting the reel to position g g
Opening the chuck & Removing the Shell g g g g
Loading new shell into the shaft & locking the chuck g g g g
Loading the cartridge into let-off & locking g g
Plug the Brake hose g g
Liner wind off in the shell g
Feeding the shoulder cushion in conveyor g
Monday, August 13, 2018
How to convert External in to Internal
Eliminate 9 Activities
WHY?
Major Activities involves 119 seconds
WHY ?
Non Value Added activities are More
Root Cause: WHY ?
Multiple Manual Setting are involved
Idea: Eliminate Multiple Manual setting
Counter Measure/Kaizen- Keyword
Manual Control Gravity Control
Monday, August 13, 2018
How to convert External in to Internal
Monday, August 13, 2018
How to convert External in to Internal
Washroom Paper Holder
Functioning on Gravity
Monday, August 13, 2018
How to convert External in to Internal
Monday, August 13, 2018
How to convert External in to Internal
Before After
Cartridge setup Cartridge setup
Before After
Improvement Improvement
Monday, August 13, 2018
How to convert External in to Internal
Monday, August 13, 2018
Results - Benefits
Time saving/loading/machine 131 secs
300 No. of Changes/day/machine 20
250 Time saving/machine/day 1965 secs
240
200 Tyre Gained/machine/day 12 tyres
Changeover Time in
secs./changeover
150 Tyre Gained- 9 machine /day 108 tyres
100
50
109
Loss109Reduction
0
Substantially
Shoulder Cushion
Bench Mark
Increased
Target Actual
the Capacity Kaizen 5000
No. of Tyres/day
To Meet the Market Demand
4608
Setup Time Reduced in Shoulder Cushion Other
Kaizens
assembly from 240 to 109 secs
4500
Before After After
Monday, August 13, 2018
Standardization
PM checklist Updated for Modified cartridge
CLIT checklist updated for the new method
Horizontally Deployed to all remaining Machines
Work Instruction updated for the new setup changeover & Trained the Members
Monday, August 13, 2018
Kaizen Sheet
Thank You
Monday, August 13, 2018
