Setup time is one of the major losses in a manufacturing unit. Normally, a change over may consume few hour every day. On the lower side, if our one change-over takes one hour, we straight away lose 5% of the shift time. So, usually, production managers will try to avoid the changeovers as much as possible. One of the easiest ways to minimise the loss due to setup time is to increase the batch size. For each order, they calculate the economic order quantity (EOQ) and accumulate orders until the EOQ is reached.
The inflated batch size causes the wastes of Over production, Inventory, Waiting, Over Processing, Transport in the shop floor.
SMED tries to reduce the impact of changeover time by reducing the time taken for the changeover. By reducing changeover times, the organisation can dramatically reduce their batch sizes. The movement of small batches through production line will reduce the waiting time, over production, over processing. This indeed helped Toyota in improving their flow and attain Lean with reduced cash to cash cycle times.
Benefits to Organisation
Reduce Changeover times across the plant
Improve machine availability and in-turn OEE
Reduce Minimum Batch Quantity
Reduce your batch sizes
Plan your orders well and accommodate urgent orders
Improve Productivity and reduce wastes
Make your operations more flexible with quantity and variants
Benefits of SMED
Target Audience
Level of People
Supervisor, Senior People from shop-floor
Entry Level and Middle-Level Managers
Functions
Production
Production planning
Quality
Maintenance
Industry
Manufacturing
Engineering
Automobile
Chemical
Pharma
Food
FMCG
Services
Course Contents
Orientation
What is Business?
Why are customers paying money?
Why keep customers happy?
What is Quality & Productivity?
Overview of Business Improvement Initiatives
What is Flow Production
The philosophy
Lean and Velocity
How to achieve flow?
What are the challenges for achieving flow?
Machine Layout
Economic Batch Quantity
Cost of Manufacturing Vs EBQ
SMED
Step by step approach to reducing changeover time
Choosing right machine for demonstration
Choosing right product changeover for study
Observation of Current Changeover Process
Classification of Activities
Segregation of Activities into 2 classes
Converting internal Activities into external activities
Reducing time for external activities
Reducing Time required for internal activities
Tips for Effective SMED
Templates and Roadmaps
Training Methodology
Learning by
Classroom sessions
Observations: Audio-visual
Playing: Poka-yoke games & Quiz
Course Duration
1 Day – 8 Hours
Batch Size
Min 10 and Max 20 Participants per batch
Additional Support
Continued coaching and hand-holding support could be provided by CSense after the workshop for successful project completion, as an optional engagement. We can also extend the support in other areas
By admin
May 21, 2017
