Single-minute exchange of die

Definition

Single-minute exchange of die (SMED) is a set of techniques aimed at reducing the time it takes to complete equipment changeovers. The primary goal is to minimize downtime and increase production efficiency, allowing manufacturers to respond more quickly to market demands and changes in product variety. This concept has been crucial in lean manufacturing, promoting greater flexibility in production systems.

5 Must Know Facts For Your Next Test

1. SMED was developed by Shigeo Shingo as part of the Toyota Production System, emphasizing quick changeover processes to enhance operational flexibility.
2. The concept is based on the idea that changeovers should take less than ten minutes, ideally within a single minute, hence the term 'single-minute'.
3. SMED involves separating internal and external setup tasks, allowing some preparations to be done while machines are still running.
4. Implementing SMED can lead to increased machine utilization, reduced lead times, and improved overall efficiency in production lines.
5. SMED not only benefits manufacturing but can also be applied to service industries by streamlining processes and reducing wait times.

Review Questions

• How does SMED contribute to lean manufacturing principles?
  • SMED contributes to lean manufacturing principles by reducing waste associated with long changeover times. By minimizing downtime during production transitions, it allows manufacturers to optimize their resources and improve overall efficiency. This aligns with the core objectives of lean manufacturing, which aim to eliminate non-value-added activities and enhance responsiveness to customer demands.
• Discuss the steps involved in implementing SMED and their impact on changeover times.
  • Implementing SMED involves several key steps: first, identifying all setup activities; second, separating internal tasks (those that can only be performed when the machine is stopped) from external tasks (those that can be performed while the machine is running). Next, streamlining and improving each task is essential. Finally, training staff ensures consistent application of these techniques. The impact of these steps can drastically reduce changeover times, often achieving single-minute changeovers, which enhances productivity and flexibility.
• Evaluate how adopting SMED can transform a manufacturing company's operational strategy and its responsiveness to market changes.
  • Adopting SMED can significantly transform a manufacturing company's operational strategy by fostering an agile production environment. With quicker changeovers, companies can produce smaller batches of diverse products without incurring extensive downtime or costs associated with longer setup times. This agility enables firms to better respond to fluctuating market demands, implement just-in-time practices, and enhance customer satisfaction. Furthermore, it supports continuous improvement initiatives by promoting a culture focused on efficiency and adaptability.

Related terms

Lean Manufacturing: A production practice that considers the expenditure of resources in any aspect other than the direct creation of value for the end customer to be wasteful and thus a target for elimination.

Changeover Time: The period required to switch a production process from making one product to another, encompassing both equipment adjustments and preparation steps.

Kaizen:

A Japanese term meaning 'continuous improvement,' referring to activities that continuously improve all functions and involve all employees from the CEO to the shop floor.