SMED

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Single Minute Exchange of Dies (SMED), this concept is all about the reduction in non-value added time in the production cycle. In effect the time the operator is most likely to not be using their machine to produce work, is when they have finished one job and are setting up for their next job.

SMED is applied to machines that have long set up times. The basic concept is to look at the set up process, examine all internal/external factors. Internal factors are things which happen to the machine when it is not running, it will include things like changing fixtures, awaiting for work to come off one machine, having the required skill resource, etc.

External factors are things that happen whilst the machine is running, it includes things such as awaiting for tooling stores to provide data - drawing, jigs, tooling (providing in stock!).

The next step would be to try and get much of the work to be done as an external factor whist the machine is running a job, the operator sets up for their next job. You may even find that by looking at your machines, the machine manufacturers could now provide you with multi-tooling mechanisms to reduce set up times.

Simple measures such as pre-kitting where you employ a progress person to look at a kanban control board becomes visible of what the next job for a machine operator is. The progress person would then go to the stores area and issue a kitting ticket to ensure that when an operator has completed one task the next job should at least be ready for setting up even if it is elsewhere in the production cycle. This can lead to situations where an operator may be out of work, but more often than not it will mean a reduction in set up times.

The progress persons role would then be to ensure that all the machines in the production cycle are properly kitted up for current and next jobs. The main advantage of applying SMED is a reduction in lead times.

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