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1、1,A STRATEGY FOR PERFORMANCE EXCELLENCE,SMED,( One Step Setup),Set-up and changeover reductions for equipment, tooling and machines.,2,Executive Overview,Participant manual,Tools Workbook,Knowledge Breakthrough,Lecture notes,Lecture notes,Performance Excellence Series Training Module Elements,3,Sess
2、ion 1.0 Introduction. 4 Session 2.0 Waste Management . 12 Session 3.0 Setup Practices 22 Session 4.0 Traditional /Strategic Setup Approach 29 Session 5.0 SMED Implementation Planning. 34 Element 5.1 Implementation Team 36 Element 5.2 Implementation Plan. 37 Element 5.3 Communication Plan. 38 Element
3、 5.4 Training Plan. 40 Element 5.5 One Step Setup 42 Element 5.5.1 Separate Internal from External Setup 44 Element 5.5.2 Integrating Internal into External Setup. 49 Element 5.5.3 Reducing Setup Processing Time. 63 Element 5.5.4 Optimizing Setup Processes 92 Element 5.6 Verification & Standardizati
4、on 95 Session 6.0 Summary 105,Table of Contents Knowledge Breakthrough,SMED,4,SMED is Continuous Improvement,It is a customer driven requirement. Customers are demanding: Product and service diversity Lower costs Higher reliability and quality. In essence organizations need to become leaner ! So org
5、anizations must: Produce smaller lots, more frequently. Expand the scope and diversity of products and services. Reduce quality defects.,5,Ultimately, SMED focuses on reducing changeover and set-up times, thus enabling organizations to:,Produce smaller lots of products and services more frequently !
6、 Develop a broader scope of products and services ! Reduce quality defects towards zero !,Meet Customers Expectations !,6,What Does Set-up/changeover reduction mean for my business?,Increased customer service levels and profits ! Via Waste Elimination resulting in: Reduced Lead Times-Faster Delivery
7、 Zero Inventories-Reduced Working Capital Improved Quality Improved Safety Smaller lots of products-flexibility Diversified Product & Service Options,7,To eliminate the wastes that result from “uncontrolled” processes increasing inventories and lead times To gain control on equipment, material & inv
8、entory. Apply Control Techniques to Eliminate Erosion of Improvements. Standardize Improvements for Maintenance of Critical Set-up Parameters.,Look Familiar?,Why SMED ?,8,Major CPI Tools (6s) Kaizen Lean Description Cp/Cpk 4 Process capability assessment DOE 4 Design of experiments SPC 4 Process con
9、trol based on statistics and data analysis FMEA 4 Risk assessment tool Regression 4 Correlate effect one variable has on another Process Map 4 4 4 Map process steps to communicate and identify opportunities 5 whys /2 hows 4 4 4 Determination methods for root cause discovery Pareto 4 4 4 Column chart
10、 ranking items highest to lowest Fishbone 4 4 4 Cause / Effect Diagram 5S 4 4 Elimination waste Visual Mgmt 4 4 4 Emphasis on visual techniques to manage process Poka-Yoke 4 4 Error proofing techniques Spaghetti Chart 4 4 Kanban 4 4 Material storage technique used to control process Takt Time 4 4 De
11、termine pace or beat of a process Std Work 4 4 Evaluate tasks done during a process SMED 4 4 Single minute exchange of dies - Quick machine set up TPM 4 Integrate maintenance strategy with process Cellular Flow 4 Reduce inventory & cycle time through process layout and pull production techniques,Exp
12、and Process Improvement Program to Utilize Kaizen Tool Kit,Tool Kit Comparison,9,Identify what types of internal and external setup times are involved in the following pictures.,Picture A: Wire Cutting Machine,Picture B: Metal Stamping Machine,10,Identify what types of internal and external setup &
13、times are involved in the following pictures.,Picture A: Wire Cutting Machine,Picture B: Metal Stamping Machine,_,_,Setup Type,Setup Type,Time ( Min),Time ( Min),Think Break,11,Internal External Setup,Classify Three items under each item category.,External,Internal,_,_,Which items would you convert from internal to external Setup ? _ Why? _,Think Break,12,Traditional Setup Practices,Material move
