SMED

Definition

Single-Minute Exchange of Die (SMED) is a lean manufacturing technique aimed at reducing the time it takes to switch from one production task to another. The goal is to achieve setup times of less than 10 minutes, which improves operational efficiency and flexibility. By streamlining setup processes, SMED enhances productivity and minimizes downtime, allowing for more responsive production systems that can better meet customer demands.

5 Must Know Facts For Your Next Test

1. SMED was developed by Shigeo Shingo, a key figure in the Toyota Production System, focusing on minimizing setup times.
2. The SMED methodology divides setup activities into internal and external tasks, aiming to convert as many internal tasks as possible to external ones.
3. Implementing SMED can lead to reduced inventory levels, shorter lead times, and improved product quality by enabling more frequent changeovers.
4. A successful SMED implementation can significantly increase machine utilization rates since equipment is not idle during lengthy changeovers.
5. Companies adopting SMED often report enhanced flexibility in responding to customer needs due to their ability to switch between products quickly.

Review Questions

• How does SMED contribute to lean manufacturing practices in an organization?
  • SMED contributes to lean manufacturing by reducing setup times, which directly decreases waste associated with downtime and inefficiency. By streamlining changeover processes, organizations can increase production flexibility and responsiveness to market demands. This aligns with lean principles that prioritize maximizing value while minimizing waste, ultimately leading to more efficient operations.
• Discuss the steps involved in implementing a successful SMED program within a manufacturing facility.
  • Implementing a successful SMED program involves several key steps: first, identify the current setup process and measure the time taken for each step. Next, categorize tasks into internal and external, then focus on converting as many internal tasks as possible into external ones that can be done while machines are still operating. Streamlining remaining internal tasks and standardizing procedures follow. Lastly, continuous training and feedback ensure the SMED process evolves with production needs.
• Evaluate the impact of effective SMED practices on overall operational performance and customer satisfaction in a competitive market.
  • Effective SMED practices have a profound impact on operational performance by significantly reducing changeover times, which increases machine utilization and decreases lead times. This allows companies to produce smaller batches of products more frequently, leading to better inventory management and reduced holding costs. As a result, organizations can respond quickly to customer orders and adapt to changing market conditions, ultimately enhancing customer satisfaction and competitive advantage.

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: The process of switching from producing one product or part to another, often requiring adjustments to machinery or tools.

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