Focus Areas

• Operational and Financial Impact of reduced set up time and objectives to reduce the same
• 5 step actions to reduce set up time
• Formats, analysis, proposed solutions to reduce set up time
• 5 Why analysis of internal set up time element – an example
• Spagetti diagram for motion analysis
• Few Set up reduction Kaizens from various organizations
• Industry case study examples with complete project presentation
• Example of a Visual Set up SOP
• Deployment steps and journey forward

Background

Setup time reduction or Quick Change over by SMED technique is a very important and useful tool to Improve Productivity, Reduce Lead time, Serve multiple customers’ requirements by producing in smaller batches and delivering On-time. SMED is a pre-requisite to achieve ‘Just-in-time’ production and delivery.
Reducing setup time reduces overall plant WIP significantly, reduces quality defects, eliminates overproduction based on market forecast, eliminates bottlenecks and increases plant capacity, improves higher fixed cost absorption by better asset utilization, reduces variable cost per unit and overall manufacturing cost per unit.
SMED is a very simple tool with little or no cost and easy to implement by engaging shopfloor workmen, supervisors and managers. This makes SMED one of the most used tools across the world across all types of Manufacturing organizations, irrespective of type of products, process and size.
Keeping this in view, IMTMA is organising an online training on SMED (Single Minute Exchange of Dies) for Quick Change over.

Key Takeaways

• Collect set up loss data
• Identify Set up reduction projects on priority by analyzing the data
• Study (action, time, motion) identified set up activities in detail, conduct events and engage teams to find out ideas, actions to reduce set up time
• Follow structured steps for set up time reduction
• Use the training materials and various examples as reference for implementation

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