SMED
- Single Minute Exchange of Die
Single Minute Exchange of Die (SMED), or Fast Changeover, is as the name suggests the method
by which equipment can be changed from one product to
the next in the most effective way, and in the shortest
possible time.
Single Minute Exchange of Die is an
objective whereby all changeovers are completed in a
single number of minutes (less than 10). S.M.E.D. is
an integral part of T.P.M. (Total Productive Maintenance)
where one of the six major losses is changeover.
Manufacturers often produce products in much longer
runs than their customers actually require in order
to achieve economies of scale, this is also known as
producing in economic batch quantities. The economic
batch quantity refers to the ratio between actual production
time and changeover. Obviously the longer the production
run in relation to the changeover time, the more efficient
the process would appear.
The problems with large batch manufacture
are:
- Businesses are inflexible; it is uneconomic to
change products over at short notice.
- Large amounts of stock, or work in progress are
created, and have to be stored.
- Stock can easily become damaged or obsolete.
- Large runs promote the problem of undetected defects.
The rationale behind SMED is that:
if changeovers can be carried out in shorter times,
then production runs can be reduced accordingly, reducing
or eliminating all of the above problems.
By implementing SMED organisations can manufacture products
at times, and in quantities, much closer to what, and
when, their customers require them.
The Lean
Group have extensive experience helping clients implement
SMED often the seemingly impossible is achieved, with
typical changeover reduction activities resulting in
a reduction in tool change times, of between 50 & 90%.
Satisfying customer demand from the
manufacturing process rather than from stock has a significant
impact on the levels of finished goods stock and its
associated cost. Often warehouses previously required
for the storage of stock can be redeployed for use in
activities that actually add-value to the business rather
than act as a drain.
Benefits of
SMED Summary:
- - Smaller Batch Sizes
-
- Increased Flexibility
-
- More Frequent Changeovers
-
- Reduced Inventory
-
- Reduction in Waste
-
- Reduction in Start-Up Losses
-
- Improved Equipment Utilisation
-
- Maximise the Return
on Buildings
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