What is Single Minute Exchange of Dies (SMED)?

Mastering Single Minute Exchange of Dies (SMED) for Efficient Production

Does your production process experience long and drawn-out changeovers, causing significant downtime and a loss of productivity? If so, Single Minute Exchange of Dies (SMED) might be the solution you need. SMED is a lean manufacturing methodology aimed at drastically reducing changeover times—bringing them down to less than 10 minutes. By applying SMED, you can optimize your changeover process and minimize disruptions to your production flow. In this blog, we’ll explore the key principles of SMED and walk through the steps for its successful implementation.

Understanding Internal and External Actions

In SMED, the actions performed during a changeover are classified into two categories: internal and external actions. These categories are essential to understanding how SMED works and how it can streamline your processes.

Internal Actions

Internal actions are those tasks that can only be carried out when the machine is stopped. This is the phase of the changeover where production must come to a halt. Examples of internal actions include adjustments, calibrations, and setting up the machine for the next product. These activities contribute to downtime and are a major focus for improvement in SMED.

External Actions

On the other hand, external actions are tasks that can be performed while the machine is still running. These activities don’t contribute to downtime and include things like preparing tools, materials, or cleaning up from the previous run. The more activities you can shift from internal to external actions, the shorter your changeover times will be.

The Steps of SMED Implementation

To implement SMED, there are several key steps that need to be followed. Each step is designed to make your changeover process faster and more efficient, minimizing downtime and maximizing productivity.

1. Analyze the Current Process

The first step is to analyze your current changeover process. Identify bottlenecks and changeovers that take longer than necessary or require excessive resources. Observe and measure how long your changeovers take and identify which tasks are internal and which are external. This analysis will provide a baseline for improvement.

2. Separate Internal and External Actions

The next step is to separate internal and external actions. This involves carefully observing the changeover process to identify tasks that could potentially be shifted from internal (requiring machine stoppage) to external (performed while the machine is still running). For example, if tooling preparation can be done while the machine is still running, it should be classified as an external action.

3. Convert Internal Actions to External

Once internal and external actions are identified, the goal is to convert as many internal actions to external as possible. This reduces the amount of time the machine is idle. For instance, preheating equipment, staging tools, or preparing materials in advance are all ways to externalize tasks. By doing this, you can perform much of the setup work while the machine is still operational, cutting down on unnecessary stoppages.

4. Streamline Internal Actions

The next step is to streamline the remaining internal actions. This can be done by upgrading equipment, automating processes, and standardizing procedures. The goal is to reduce the time spent on activities that require the machine to be stopped. For example, adjusting machinery settings or installing quick-release mechanisms can help reduce setup times. Simplifying and organizing these tasks ensures that when the machine must stop, it does so for the shortest possible time.

5. Optimize External Actions

Finally, optimize the external actions to ensure they are as efficient as possible. Keep tools and materials organized and within easy reach to speed up the changeover process. Make sure that workspaces are clean and that everything needed for the next production run is prepared in advance. A well-organized workspace can significantly reduce the time spent on external activities, making the overall changeover process faster and smoother.

The ElSeSiCoA Approach

A practical approach to SMED is the ElSeSiCoA method, which stands for Eliminate, Sequence-adjust, Simplify, Combine, and Automate. These steps are designed to make the changeover process faster and more efficient.

• Eliminate: Remove any non-critical tasks that do not add value to the changeover process. For example, eliminate unnecessary steps that contribute to downtime.
• Sequence-adjust: Rearrange tasks to ensure they are performed in the most efficient order. This helps minimize setup times and keeps the process flowing.
• Simplify: Simplify tasks whenever possible to reduce complexity and the chance of errors. This could involve using simpler tools or reducing the number of steps in the process.
• Combine: Where possible, combine tasks that can be performed simultaneously. For example, if two tasks can be done by different operators at the same time, combine them to save time.
• Automate: Introduce automation to speed up repetitive tasks. Automating processes such as tool changes or material handling can significantly reduce changeover times.

Iterative Improvement and Future Guidelines

Mastering SMED is not a one-time task but an ongoing process of improvement. Each time you perform a changeover, aim to reduce the time taken by 45%. This iterative improvement ensures that your production line becomes more efficient over time. Document the new procedures and provide clear guidelines for future changeovers to maintain the improvements made.

Wrapping Up

The Single Minute Exchange of Dies (SMED) method is a powerful tool that enables manufacturers to reduce downtime and make their production processes more flexible. By separating internal and external actions, converting tasks where possible, and optimizing both internal and external processes, companies can reduce changeover times to less than 10 minutes.

Implementing SMED allows businesses to be more agile, responsive to customer demands, and efficient in their operations. If your production line is losing valuable time due to long changeovers, SMED provides the blueprint to dramatically improve performance, reduce downtime, and push your business toward higher productivity and success.

Now is the time to incorporate SMED principles into your operations, harness its power, and unlock a new level of efficiency in your manufacturing processes.