SMED Training

• Purpose & benefits of SMED
• SMED Fundamental: Internal & External Activities
• Importance of separating internal & external activities as the foundation of SMED
• Difference between Internal and External Activities

Step 1: Study & Identify Tasks

• Learn to capture activities of each operator with communication and involvement of operators 
• Learn to maintain time study sheet along with time taken for each activity
• Categorise each activity into Internal and external activities
• Conduct Pareto analysis to identify high time consuming activities, to be taken in priority for improvement

Step 2:  Separate Internal and External tasks

• Learn to cover activities that can be done externally before or after stopping the machine 
• Arrange required materials and tools using a checklist to ensure everything is available
• Use of point of techniques to arrange tools and trolleys to where it will be required 
• Removed parts transportation & paperwork training before or after stopping the machine
• Conduct function checks on machines to avoid any failures or process troubles during the changeover

Step 3: Convert Internal tasks into External tasks

• Understand each internal activity using ECRS technique to check if it can be eliminated, combined, reduced or simplified.
• Learn to convert internal into external activities using methods like pre-assemble of parts, pre-heating of moulds, standardization of part heights or sizes 

Step 4: Reduce Internal time

• Use of Parallel work to identify activities that can be done in parallel, rather than in sequence
• Use of workload balancing sheets to divide work between the team members doing the changeover
• Use Standard work for each person involved in the changeover
• Using fastening and unfastening during changeovers 

Step 5: Reduce External Time

• Track target vs actual to see progress on changeover time visually on gemba
• Learn to identify reasons of downtime, by sub assemblies, byparts
• Conduct abnormality identification on identified issues to help reduce post changeover downtimes

SMED Case Study

Walk through each step of the SMED process and its resulting impact on efficiency, downtime, and production flow covering following improvements:

• Use of the checklist to eliminate waiting time for any parts / Tools
• Use of additional parts / Two bin system for cleaning
• Use of special tools for reducing floor cleaning time
• Pre arrangement of all parts to reduce Waiting times / Preparation of labels
• Saving in cleaning time through Standard Work

Actual changeover study on shop floor

Conduct actual changeover study of selected fast moving product and high frequency changeover

• Form teams, conduct time study by different teams
• Generate ideas for improvement, prepare action plan, do trial for next batch
• Implement changeover improvements

Standardise and Sustain

Improvements done must be sustained by establishing standards and tracking actual results vs standards. Any deviation from standards to be analysed and corrective actions to be taken.