The Single-Minute Exchange of Die, or SMED, is a method that has the potential to trim changeover times to less than ten minutes. It’s a meticulous process where every element of the changeover is examined—with a keen eye for removal, relocation, simplification, or streamlining.

Stay with us as we delve deeper into the intricacies and implications of SMED.

What is SMED?

SMED is designed to significantly reduce the time taken to perform equipment changeovers, a critical aspect in manufacturing. The key strategy of SMED is to convert as many changeover steps as possible into ‘external’ tasks – those that can be executed while the equipment is running. Any remaining steps are simplified and streamlined for efficiency. The term ‘single-minute’ reflects the ambitious objective of this approach: To bring down changeover times to under 10 minutes. Thus, SMED serves as a lean tool in manufacturing, enabling swift transitions from one product processing to the next.

The Basics of SMED

This system is engineered to minimize the time required for equipment changeovers, a crucial aspect in manufacturing operations.

Here are some key takeaways about SMED:

• It encourages workers to execute as many steps as possible prior to the actual changeover, thereby saving valuable time when the equipment is halted.
• It promotes the idea of teamwork, with multiple tasks being carried out concurrently, effectively shortening the changeover duration.
• It advocates for a standardized and optimized workflow, ensuring each step is performed efficiently and consistently.

The ambitious aim of SMED is to slash changeover times from hours to less than 10 minutes, hence the term “Single Minute”. The “Exchange of Dies” part refers to the swapping of specialized manufacturing tools during production model changes which inevitably lead to downtime.

The brain behind the SMED system was Shigeo Shingo, a Japanese industrial engineer who made significant strides in reducing changeover times. In fact, companies that implemented Shingo’s methods saw an average reduction in changeover times by 94%.

While it may seem improbable to reduce machinery replacement times to under 10 minutes, in most cases, with the right application of the SMED principles, it is indeed achievable.

SMED Benefits

Streamlined Lot Sizes

The nimbleness of efficient changeovers paves the way for smooth transitions between product batches, permitting manufacturers to deftly switch from one lot to another. Smaller lot sizes result in a domino effect of benefits: diminished inventory costs, waste reduction, and decreased space requirements for material storage and handling.

Cutback in Manufacturing Expenses

The integration of augmented reality and the Industrial Internet of Things (IIoT) to curtail changeover times and manage planned maintenance can lead to significant cost savings. Manufacturers can pare down direct material costs and slash scrap production by an impressive 50%.

Boost in Machine Efficiency

The implementation of SMED can enable changeover halts to occur even while machines are still operational and smoothen material workflows post-changeover, resulting in quicker start-up times.

Enhanced Adaptability to Customer Demand

The benefits of managing smaller lot sizes, scheduling less frequent maintenance, and having streamlined workflows contribute to a more flexible production schedule. These advantages also set the stage for more effective production planning, aligning manufacturing teams more closely with customer needs.

How to Implement SMED

Implementing a SMED process begins with identifying the least efficient facets of your current operations. Harnessing the power of the Industrial Internet of Things (IIoT), manufacturers can gain real-time insights into all assets, pinpointing areas that lack optimal efficiency. Before zeroing in on an area for SMED application, consider these elements of production:

• Long duration of changeover time
• Variability in changeover time
• Regularity of changeovers, allowing for performance measurement
• Employee familiarity with the equipment
• Equipment serving as a bottleneck for other processes

After a thorough analysis of these areas, you can embark on the four-stage journey of SMED implementation to curtail changeover times.

Pilot Area Identification: The crux of pinpointing your pilot area lies in ensuring your employees are not only confident but also motivated to enhance performance. Augmented reality technology can simplify complex aspects of manual changeovers. Employees can follow digital work instructions step-by-step using 3D visualizations overlaid onto their work environments. This approach boosts information retention among frontline workers, improving their comprehension of the changeover process and minimizing error-induced scrap or rework.

Internal and External Components Recognition: With your test area established, it’s crucial to understand both the internal and external components of the changeover. This requires an understanding of the tasks at hand and the time taken for each. The SMED system hinges on two key elements during changeovers:

• Internal Elements: Tasks that must be completed while the equipment is halted.
• External Elements: Tasks that can be executed while the machinery is operational. One focus here is ensuring tools and supplies for changeovers are readily available.

Conversion of Internal Components to External: The essence of SMED lies in transforming as many elements as possible from internal to external. Each component should be examined to determine if it can be handled while the machine is still operational. The IIoT’s ability to gather enterprise-wide data on assets, processes, and procedures aids this conversion, thereby reducing overall changeover time.

Streamlining of Internal Elements:  After identifying your external elements, the remaining internal elements must be streamlined. A smart connected factory powered by IIoT solutions can facilitate this process, enhancing productivity and mitigating inefficiencies.

What You Should Do Next

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