Single Minute Exchange of Die
(SMED)Raghavendra ParadkarMurtaza DalalUzair PatelShamsher PathanNeha Jaiswal
MEANING OF A SET UP TIME
Study blueprints
Get tools and gauges
Select and secure Fixture
Mounting, adjustments, feeder
QA inspection, pilot run
Count the jobs produced
Remove tools, mountings, fixtures
Cleaning
LEAN MANUFACTURING
Reducing waste
Increasing productivity
Innovative practices
Inculcating good management systems
Continuous improvement
LM Techniques 5S System
Visual Control
SOPs
JIT
KANBAN System
Cellular Layout
Value Stream Mapping
Poka Yoke
Single Minutes Exchange of Dies (SMED):
TPM
Kaizen Blitz
SMED
“Applying Ingenious methods, to bring set up
time to less than 10 minutes”.
One-Touch Exchange of Die>>changeovers
less than 100 seconds
HISTORY
The concept arose in the late 1950s -1960s
Shigeo Shingo >> Toyota
Bottlenecks at car body-moulding presses
Long tool changeover times
Drove up production lot sizes
Direct impact on Productivity
OBSERVATIONS
Most difficult tools to change >>dies on the
transfer-stamping machines that produce
vehicle bodies
The existing process took from twelve hours
to almost three days to complete
IMPLEMENTATIONS
Place precision measurement devices on the
transfer stamping machines
Record the necessary measurements for each
model's die
Scheduling the die changes in a standard
sequence
Toyota cut the change-over time to less than 10
minutes per die
BENEFITS OF SMED
Reduce batch size
Reduce lead time
Reduce inventory
Reduce scrap
Increase efficiency
Increase flexibility
SMED in Toyota factory
SMED in Formula 1
MAINTENANCE
MAINTENANCE DEFINITION
“Maintenance is a set of organised activities
that are carried out in order to keep an item in
its best operational condition with minimum
cost acquired”.
cont….
The combination of all technical and
administrative actions.
Including supervision actions, intended to retain
an item in, or restore it to, a state in which it can
perform a required function
Repair or replacement activities
PLANT
MAINTENANCE
Reduce Breakdowns
Reduce Downtime
Improving Equipment Efficiency
Improving Inventory Control
Maximising Production
Optimising Resources Utilisation
Optimising Useful Life of Equipment
Minimising Energy Usage
Providing Budgetary Control
TYPES
Run to Failure Maintenance (RTF)
Preventive Maintenance (PM)
Corrective Maintenance (CM)
Improvement Maintenance (IM)
Predictive Maintenance (PDM)
BREAKDOWN MAINTENANCE
Repairs are made after the equipment is failed
Machine can not perform its normal function
anymore
Bring this machine to at least its minimum
acceptable condition
It is the oldest type of maintenance
WHERE TO USEThe failure of a component in a system is
unpredictable.
The cost of maintenance is lower than other activities of other types of maintenance.
Financial justification for scheduling are not felt
DISADVANTAGES
Poor and hurried maintenance
Safety issues for both workers and machines
Delay in production & reduces output
Direct loss of profit
Preventive Maintenance (PM)
“Prevention is better than cure”
“Stitch-in-time”
Locates weak spots of machinery and equipments.
Periodic/scheduled inspections
Minor repairs to reduce the danger of unanticipated
breakdowns.
FACTORS OF PM
Adequate staff in the dept.
Qualified and skills (ITI)
The right choice equipment.
The support from management
Planning and scheduling of PM programme.
The ability to properly apply the PM programme
Classification of PM
Routine maintenance
Running maintenance
Opportunity maintenance
Window maintenance
Shutdown preventive maintenance
ADVANTAGES
• Reduces break down & down time
• Less odd-time repair and reduces over time of crews
• Greater safety of workers
• Lower maintenance and repair costs
• Less stand-by equipments and spare parts
• Better product quality and fewer reworks and scraps
• Increases plant life
• Increases chances to get production incentive bonus
THANK YOU