SMED: How to Design Machines with High OEE

Single-Minute Exchange of Die (SMED) is a methodology developed by Shigeo Shingo aimed at drastically reducing the time required for machine setups in production. This reduction directly increases machine availability, a key component of production efficiency. This article delves into how to design machines considering SMED principles to achieve high OEE.

Lean Manufacturing Principles

Foundations of Lean Manufacturing

Lean Manufacturing is a production management philosophy focused on maximizing customer value while minimizing waste. Lean emphasizes continuous process improvement and the elimination of unnecessary activities, leading to increased efficiency and reduced production costs.

Key Lean Tools

Lean Manufacturing employs various tools to achieve its goals, including:

• Kaizen: A method of continuous improvement involving all employees in the process of enhancing company operations.
• 5S: A workplace organization system involving sorting, setting in order, shining, standardizing, and sustaining discipline.
• Just-In-Time (JIT): A production system that delivers materials and components exactly when needed, minimizing inventory.
• SMED: A key Lean element focusing on quick machine setups, allowing flexible responses to changing production needs.

SMED – Single-Minute Exchange of Die

Definition and Principles of SMED

Single-Minute Exchange of Die (SMED) is a method aimed at drastically reducing machine and production line setup times, introduced by Shigeo Shingo. The primary goal of SMED is to reduce setup time to a single-digit number of minutes (less than 10 minutes). Key SMED principles include:

1. Separating internal and external activities:
   • Internal activities can only be performed when the machine is stopped.
   • External activities can be performed while the machine is running.
   • The first step in SMED is to identify and convert as many internal activities as possible into external ones.
2. Standardizing and simplifying internal activities:
   • Standardizing tools and work methods to ensure all operations are performed consistently.
   • Simplifying and speeding up actions that must be performed when the machine is stopped.
3. Implementing quick-changeover systems:
   • Using systems that allow for quick attachment and detachment of tools and machine components.
   • Employing quick-release elements that minimize the need for adjustments and calibrations.
4. Conducting training and engaging employees:
   • Training machine operators and production teams on new SMED procedures and techniques.
   • Involving employees in the improvement process and seeking further opportunities to reduce setup times.

Implementing the SMED Process

Implementing SMED can be divided into several key stages:

1. Analyzing the current setup process:
   • Thoroughly monitoring and documenting all setup-related activities.
   • Identifying internal and external activities and their durations.
2. Converting internal activities to external ones:
   • Assessing the feasibility of transferring internal activities to external ones.
   • Implementing new procedures that allow for more activities to be performed while the machine is running.
3. Optimizing internal activities:
   • Standardizing and simplifying internal procedures.
   • Introducing quick-changeover systems and tools.
4. Training and engaging employees:
   • Conducting training for operators and production teams.
   • Encouraging active participation in the improvement process.
5. Monitoring and continuous improvement:
   • Regularly monitoring results and setup times.
   • Implementing employee suggestions and seeking further improvements.

Success Stories of SMED Implementation Across Industries

Implementing SMED has yielded significant benefits across various production industries:

• Automotive Industry:
  • In car manufacturing plants like Toyota, SMED application significantly reduced setup times, contributing to increased production flexibility and faster introduction of new models to the market.
• Food Industry:
  • In food production companies like Nestlé, SMED facilitated quick transitions between different products on production lines, reducing downtime and increasing production efficiency.
• Electronics Industry:
  • In electronics manufacturing plants, SMED enabled faster adaptation of production lines to different product series, enhancing competitiveness in a dynamic market.

Production Automation and SMED

The Role of Automation in SMED

Automation plays a crucial role in reducing setup times, a central goal of SMED. Modern technologies and automation solutions can speed up many processes previously performed manually, requiring significant labor and time. Automation can support SMED in several key areas:

1. Quick tool clamping and release:
   • Automatic tool clamping systems can significantly shorten the time needed for their replacement. These systems eliminate the need for manual tightening and adjustments, reducing setup times and error risks.
2. Automatic machine parameter settings:
   • Systems that automatically set machine parameters according to production requirements allow for quick and accurate machine adaptation to new tasks. This avoids manual programming and minimizes setting errors.
3. Robotics and automation of auxiliary processes:
   • Using robots to perform repetitive and time-consuming tasks, such as material handling, can significantly speed up the entire setup process.
4. Real-time data monitoring and analysis:
   • SCADA (Supervisory Control and Data Acquisition) systems allow real-time monitoring and analysis of production processes. This enables quick identification and elimination of bottlenecks and optimization of setup processes.

SCADA Systems and Their Impact on SMED

SCADA systems play a crucial role in monitoring and optimizing setup processes within SMED.

SCADA enables the collection and analysis of data from machines and production processes in real-time, which is essential for quick and effective setups.

1. Monitoring setup times:
   • SCADA allows precise tracking of setup times, enabling the identification of areas needing optimization. With accurate data, more informed improvement decisions can be made.
2. Analyzing downtime causes:
   • SCADA systems can record and analyze downtime causes, allowing for quick problem identification and elimination. This minimizes downtime and increases machine availability.
3. Integration with ERP and MES systems:
   • Integrating SCADA with ERP (Enterprise Resource Planning) and MES (Manufacturing Execution Systems) enables comprehensive production process management. This improves planning and coordination of setups, increasing production efficiency.

POKA-YOKE – Quality Assurance

Definition of POKA-YOKE

POKA-YOKE is a Japanese error-proofing technique that involves designing production processes to make errors impossible or easily detectable and correctable. This technique aims to eliminate defects and enhance product quality.

Purpose and Principles of POKA-YOKE

1. Error Prevention:
   • The primary goal of POKA-YOKE is to eliminate errors at the design stage of production processes, avoiding costly corrections and downtime.
2. Error Detection and Correction:
   • In cases where errors cannot be entirely eliminated, POKA-YOKE ensures their rapid detection and correction before affecting the final product.
3. Simplicity and Effectiveness:
   • POKA-YOKE solutions should be simple and easy to implement, allowing effective use by workers on the production line.

Examples of POKA-YOKE Applications in Production

• Automotive Industry:
  • In car production, various POKA-YOKE solutions are used, such as sensors and indicators that prevent incorrect assembly or improper force application.
• Electronics Industry:
  • In electronics component production, POKA-YOKE may involve special connectors and holders ensuring correct connections and eliminating assembly errors.
• Food Industry:
  • In food production plants, POKA-YOKE may involve sensors detecting foreign objects in products, ensuring compliance with quality and safety standards.

Impact of POKA-YOKE on SMED

1. Reduction of Production Defects:
   • With POKA-YOKE, setup processes can be designed to minimize error risks, resulting in higher product quality and reduced downtime risk.
2. Increased Process Reliability:
   • Applying POKA-YOKE in setup processes enhances the reliability and repeatability of these operations, crucial for effective SMED implementation.

TPM (Total Productive Maintenance) and SMED

What is TPM?

Total Productive Maintenance (TPM) is a comprehensive approach to maintenance that involves all employees to maximize equipment efficiency.

TPM includes activities such as preventive maintenance, autonomous maintenance by operators, and continuous process improvement.

Pillars of TPM

1. Autonomous Maintenance:
   • Operators are responsible for daily machine maintenance, including cleaning, lubrication, and minor repairs. This keeps machines in better condition and reduces the likelihood of breakdowns.
2. Preventive Maintenance:
   • Regular inspections and maintenance prevent unexpected failures and extend machine lifespan.
3. Continuous Improvement:
   • Constantly seeking ways to improve equipment efficiency and reliability through data analysis and innovative solutions.

How TPM Affects Machine Availability

TPM significantly improves machine availability, a key indicator of OEE. Regular maintenance and operator involvement in maintenance processes minimize downtime and failures, enabling smooth and uninterrupted production.

SMED as a Component of TPM

SMED is an integral part of TPM because effective setups are crucial for maintaining high machine availability. Implementing SMED within TPM allows for:

1. Reduction of Setup Times:
   • With SMED, setup times are significantly reduced, increasing machine availability and allowing for more flexible production planning.
2. Increased Operator Engagement:
   • Operators responsible for autonomous maintenance are also involved in setup processes, enhancing their understanding of machines and optimizing procedures.

Key Performance Indicators (KPI) and SMED

Introduction to KPI

Key Performance Indicators (KPI) are tools that allow for measuring and monitoring the efficiency of production processes. In the context of SMED, the most important KPIs are:

1. Setup Time:
   • The time required to perform a machine setup, directly affecting production availability and flexibility.
2. MTBF (Mean Time Between Failures):
   • The average time between failures, indicating machine reliability and maintenance efficiency.
3. MTTR (Mean Time To Repair):
   • The average time needed to repair a machine, affecting downtime duration and machine availability.

Monitoring KPI in the Context of SMED

Effective monitoring of KPIs related to setup times is crucial for optimizing SMED processes. This includes:

1. Regular Data Collection:
   • Data on setup times, failures, and repairs should be regularly collected and analyzed to identify areas needing improvement.
2. Analysis and Reporting:
   • Data analysis allows for detecting trends and patterns that may indicate potential problems or optimization opportunities. Regular KPI reporting enables informed improvement decisions.
3. Utilization of IT Systems:
   • IT systems, such as ERP and MES, can support KPI monitoring and analysis, providing precise and up-to-date data on production process performance.

Utilization of IT Systems in Monitoring KPI

• ERP Systems:
  • ERP systems allow for central management of production data, enabling better planning and control over setup processes.
• MES Systems:
  • MES (Manufacturing Execution Systems) enable real-time monitoring of production processes and immediate response to potential issues. This allows for quick identification and elimination of downtime causes.

FAT and SAT Tests and SMED

Definition of FAT and SAT

Factory Acceptance Test (FAT) and Site Acceptance Test (SAT) are key tests conducted before implementing new machines or production lines.

1. FAT (Factory Acceptance Test):
   • A test conducted at the manufacturer’s facility to confirm that the machine meets all specifications and requirements before shipment to the customer.
2. SAT (Site Acceptance Test):
   • A test conducted at the customer’s site after machine installation to confirm that the machine operates correctly under actual production conditions.

Importance of FAT and SAT Tests in the Context of SMED

1. Confirmation of Functionality:
   • FAT and SAT tests verify whether the machine meets all requirements and can perform setups according to SMED principles.
2. Optimization of Settings:
   • During tests, necessary calibrations and adjustments can be made to achieve optimal setup times.
3. Operator Training:
   • FAT and SAT tests also provide an opportunity to train operators in handling new machines and SMED procedures, ensuring smooth implementation of new production processes.

Summary of Key Points

Designing machines with SMED principles in mind is crucial for achieving high production efficiency and minimizing setup times. This article discussed how SMED fits into Lean Manufacturing principles, how production automation and SCADA systems support SMED, and how POKA-YOKE, TPM, and KPIs can contribute to effective SMED implementation. FAT and SAT tests also play a significant role in verifying and optimizing setup processes.

Future and Technological Development in the Context of SMED

New technologies, such as advanced automation systems, artificial intelligence, and the Internet of Things (IoT), will play an increasingly important role in further optimizing SMED processes. Companies seeking a competitive advantage should invest in these technologies and continuously improve their production processes according to SMED principles.

FAQ: SMED