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1. What is SMED?

**Single-Minute Exchange of Die (SMED)** is a lean manufacturing technique designed to reduce the time required to change tooling or equipment setups to less than 10 minutes. "Single-minute" refers to achieving setup times in single-digit minutes (less than 10).

Purpose of SMED:

• Minimize production downtime caused by lengthy setup changes.
• Increase flexibility in manufacturing by enabling quick transitions between products or batches.
• Support Just-In-Time (JIT) production and reduce inventory costs.

Key Focus Areas:

• Separating internal and external setup tasks.
• Streamlining internal setup tasks to minimize machine downtime.
• Standardizing and simplifying the setup process.

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2. Core Concepts of SMED

A. Internal Setup Tasks:
- Tasks that can only be performed when the machine is stopped (e.g., removing old tools, installing new ones).

B. External Setup Tasks:
- Tasks that can be performed while the machine is still running (e.g., preparing tools, organizing materials).

Goal of SMED:

• Convert as many internal tasks as possible into external tasks.
• Streamline and standardize the remaining internal tasks to minimize downtime.

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3. The SMED Process: Step-by-Step

Step 1: Observe the Current Setup Process
- Monitor the entire setup process from start to finish.
- Identify all tasks and categorize them as internal or external.

Step 2: Separate Internal and External Tasks
- Clearly distinguish tasks that require the machine to be stopped (internal) from those that can be done beforehand (external).

Step 3: Convert Internal Tasks to External Tasks
- Modify procedures or use tools to prepare tasks in advance.
- Example: Preparing tools, materials, and instructions while the machine is running.

Step 4: Streamline Internal Tasks
- Simplify or eliminate unnecessary steps.
- Use quick-change tools, standardized procedures, and ergonomic improvements.

Step 5: Document and Standardize the New Process
- Create visual work instructions and train operators.
- Continuously refine the process to ensure consistency and further improvements.

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4. Tools and Techniques Used in SMED

A. Quick-Change Systems:
- Hydraulic or magnetic clamping systems to replace traditional screws or bolts.
- Modular dies or tools designed for fast attachment/detachment.

B. Visual Management Tools:
- Labels, color-coding, and diagrams to guide operators through the setup process.

C. Tool Preparation Stations:
- Dedicated areas for preparing tools, dies, and materials before the changeover begins.

D. Automation:
- Robotic systems or automated guided vehicles (AGVs) for tool exchange.

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5. Benefits of SMED

• Reduced Downtime: Shorter setup times lead to increased machine uptime.
• Increased Production Flexibility: Enables smaller batch sizes and quicker response to customer demands.
• Lower Costs: Reduces the need for large inventories and improves resource utilization.
• Enhanced Worker Productivity: Simplified processes make setup tasks easier and faster for operators.

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6. Practical Example of SMED

Scenario:
A plastic injection molding company produces containers and needs to switch molds to produce different sizes and shapes.

Before SMED Implementation:

• Setup time: 90 minutes.
• Steps involved:
    - Stop the machine.
    - Remove the old mold using manual tools (e.g., bolts and screws).
    - Clean the machine.
    - Install and align the new mold.
    - Test and adjust settings.
• Impact: Long downtime reduced production capacity and increased inventory costs.

After SMED Implementation:

• Setup time: Reduced to 9 minutes.
• Improvements Made:
    - Introduced quick-clamping systems to replace bolts and screws.
    - Prepared molds and materials at a pre-setting station while the machine was running.
    - Installed alignment guides on the machine to eliminate manual adjustments.
    - Trained operators on a standardized process for mold changes.
• Results:
    - Downtime reduced by 90%.
    - Allowed smaller batch sizes and reduced inventory costs.
    - Increased responsiveness to customer orders.

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7. Challenges in Implementing SMED

• Initial Investment: Costs for quick-change systems, tools, and training can be significant.
• Resistance to Change: Operators may be hesitant to adopt new processes.
• Complex Machine Design: Older machines may require modifications or retrofitting to support SMED techniques.

How to Overcome Challenges:

• Start with high-priority machines to demonstrate the benefits.
• Engage operators in the design and testing of new processes.
• Provide thorough training and support for smooth implementation.

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8. Applications of SMED

Industries Benefiting from SMED:

• Automotive Manufacturing: Rapidly switching tools or dies for different car models.
• Plastic Injection Molding: Quick mold changes for diverse product lines.
• Metal Stamping: Fast die changes for various sheet metal products.
• Electronics Manufacturing: Adjusting machines for different circuit board designs.

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9. Conclusion

**Single-Minute Exchange of Die (SMED)** is a critical lean manufacturing technique that enhances production efficiency, flexibility, and responsiveness. By reducing setup times to under 10 minutes, SMED minimizes waste, improves machine utilization, and supports just-in-time production.

Key Takeaways:

• SMED separates internal and external setup tasks, prioritizing efficiency.
• Quick-change tools and standardized processes are essential for success.
• SMED is applicable across a wide range of industries and manufacturing processes.