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1. What is OTED?

**One-Touch Exchange of Die (OTED)** is a lean manufacturing technique that focuses on reducing setup time in production processes. The goal is to enable **die changes (or tool changes)** in a single movement, often referred to as "one-touch," typically within **less than 10 minutes**.

Purpose of OTED:

• Minimize downtime caused by changing dies or tools during manufacturing.
• Increase flexibility in production to handle smaller batch sizes efficiently.
• Support Just-In-Time (JIT) manufacturing by reducing waste and improving responsiveness.

Key Focus Areas:

• Streamlining die/tool changes to make them simpler and faster.
• Eliminating unnecessary steps in the setup process.
• Improving machine uptime and overall equipment efficiency (OEE).

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2. Role of OTED in Lean Manufacturing

OTED is a subset of the **SMED (Single-Minute Exchange of Die)** methodology. While SMED targets reducing setup times to under 10 minutes, OTED goes further by aiming for a **one-touch changeover** or near-instantaneous changeover.

How OTED Supports Lean Principles:

• Waste Reduction: Eliminates wasted motion, waiting time, and unnecessary tool handling.
• Flexibility: Enables rapid adaptation to changing customer demands and smaller production runs.
• Flow Optimization: Supports smoother production flows by minimizing interruptions caused by lengthy changeovers.

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3. Key Elements of OTED

A. Pre-Setup Preparation:
- Ensure all tools, dies, and materials required for the change are prepared in advance.
- Use standardized carts or toolkits to organize necessary items.

B. Quick Clamping Systems:
- Replace traditional clamping systems with quick-release or magnetic clamps.
- Examples: Hydraulic clamping systems that require a single action to secure the die.

C. Automation in Changeovers:
- Use robotic systems or automated guided vehicles (AGVs) to perform die/tool changes.
- Sensors and cameras can verify the correct alignment of tools.

D. Elimination of Adjustments:
- Design dies/tools to be self-aligning to avoid manual adjustments during setup.
- Example: Using key slots or guide pins for precise placement.

E. Visual Management Tools:
- Use visual aids like color-coded labels and diagrams to guide operators during the changeover process.
- Example: Visual flowcharts for each step of the tool exchange.

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4. Benefits of OTED

• Reduced Downtime: Shorter changeovers mean machines spend more time producing and less time idle.
• Increased Production Flexibility: Makes it easier to switch between different products or batch sizes.
• Lower Inventory Costs: Enables smaller batch sizes, reducing the need for large inventories.
• Improved Operator Efficiency: Simplified processes reduce errors and increase worker productivity.
• Enhanced Customer Responsiveness: Faster changeovers support just-in-time (JIT) production and quicker order fulfillment.

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5. Practical Example of OTED

Scenario: A metal stamping company needs to change dies to switch between producing automotive parts (Part A) and appliance components (Part B).

Before OTED Implementation:

• Changeover time: 45 minutes.
• Steps involved: Stopping the machine, removing the old die, cleaning the machine, installing the new die, manual alignment, test runs, and adjustments.
• Impact: Frequent delays and reduced production capacity.

After OTED Implementation:

• Changeover time: Reduced to 5 minutes using hydraulic clamping and pre-prepared setups.
• Improvements Made:
    - Pre-setup carts organized with all necessary tools and materials.
    - Quick-release clamping systems replaced manual clamps.
    - Alignment guides on the machine eliminated the need for manual adjustments.
    - Operators trained on a standardized process for one-touch die changes.
• Result:
    - Increased uptime by 40%.
    - Allowed smaller batch sizes, reducing inventory storage costs.
    - Improved responsiveness to customer orders.

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6. OTED Tools and Techniques

A. Quick-Change Clamping Systems:
- Hydraulic, pneumatic, or magnetic clamps that secure dies/tools with minimal manual intervention.

B. Modular Dies and Tools:
- Tools designed for quick detachment and attachment, often with pre-aligned configurations.

C. Tool Pre-Setting Stations:
- Dedicated stations for preparing tools or dies before they are needed on the production line.

D. Visual Guides and Standardized Work Instructions:
- Step-by-step guides, color-coded labels, and diagrams to simplify the exchange process.

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7. Challenges in Implementing OTED

• Initial Costs: Investments in quick-change systems, modular tooling, and operator training may be significant.
• Operator Resistance: Workers may initially resist changes to established processes.
• Complex Machine Design: Older machines may require significant retrofitting to support OTED techniques.

How to Overcome Challenges:

• Start with pilot projects on high-priority machines to demonstrate results.
• Engage operators in designing and testing new processes to ensure buy-in.
• Train staff thoroughly and provide ongoing support.

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8. Applications of OTED

Industries Benefiting from OTED:

• Automotive Manufacturing: Rapidly switching between dies for different car models.
• Metal Stamping: Quick tool changes for varied sheet metal products.
• Plastic Injection Molding: Switching molds for different product designs.
• Electronics Manufacturing: Adjusting machines for different circuit board configurations.

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9. Conclusion

**One-Touch Exchange of Die (OTED)** is a powerful lean manufacturing tool that significantly improves efficiency, flexibility, and productivity. By reducing setup times to near-instantaneous levels, OTED supports just-in-time production and enhances customer responsiveness.

Key Takeaways:

• OTED is a step beyond SMED, focusing on single-motion or near-instant die/tool changes.
• Practical implementations require pre-prepared setups, quick clamping systems, and standardized processes.
• OTED is ideal for industries that require frequent product or tool changes, such as automotive and electronics manufacturing.