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Quick Die Change (SMED) Workshop
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Single Minute Exchange of Die, or SMED, is one of the cornerstones of Lean Manufacturing. Originally conceived by Japanese industrial engineer, Dr. Shigeo Shingo, focuses on the reduction of machine and die set-up time , thereby improving productivity, enabling more flexible production and reducing inventory and overall cost. The approach was quite simple: separate set-up time into "internal" (done in production, flow interrupted) and "external" (done outside of production, flow not interrupted) activities, convert as many internal activities to external activities, and then make both activities as efficient (reduce effort, cost, time, complexity, etc) as possible.
Let e-Zsigma (Canada) Inc. lead your team through a successful SMED project and enable them to reproduce the success over and over again...
Phase I - Quick Die Change (SMED) Workshop
Objectives: This one-day, interactive workshop will provide participants, via a presentation and an interactive simulation, with an introduction to Lean Manufacturing concepts and applications, with primary focus on Single Minute Exchange of Dies (SMED). The goal of this workshop will be to enable your team to successfully complete a quick die change project, as described in Phase II of this proposal. This proven Adult-Learning Model approach, (Learn-Do), has several key benefits:
- Students are able to apply what they have learned in class in a practical, real-world environment
- Proof of concept leading to rapid acceptance and adoption (change management and communication)
- Financial benefits derived from project (rapid return on training investment)
- Repeatable SMED process that your organization can leverage for future projects
Key Learnings:
Introduction to Lean Manufacturing
Kaizen, 5S and their relationship to SMED
Introduction to Quick Die Change (SMED)
The Benefits of Quick Die Change to Your Organization
The Four Basic Phases of Set-Up Reduction
The Eight Principles of SMED
Assessing the Process: Internal versus External
Set-Up Process Optimization & Continous Improvement
Who Should Attend:
Production Managers, Supervisors & Lead Hands, Engineers, Technicians, Set-up & Maintenance Personnel, Office Personnel and anyone else in your organization interested in learning how to continuously reduce change-over time in a production environment.
Phase II - Quick Die Change (SMED) Project
Objectives: Depending on the scope of the project selected, this phase of training will be conducted over a 2-3 day period, whereby a standardized methodology is followed to achieve the target goals for the project. This is a collaborative, team problem-solving process, that is facilitated by a designated project manager. In addition, e-Zsigma has incorporated basic Six Sigma methods and tools into our SMED approach, which is summarized below:
1. Define: Project scoping and planning
2. Measure: Existing Change-Over Process mapping and metrics (see note below)
3. Analyze: Change-Over SMED Process Rationalization & Data Analysis
4. Improve: Process Redesign & Optimization
5. Control: Implementation of Improvements & Control Plan
6. Realize & Leverage: Confirmation of new process entitlement and identification of leverage opportunities
7. Project Report-Out and Lessons Learned
Note: Over the last decade, video-taping of processes had risen in popularity as a tool for Lean Manufacturing process analysis (before and after improvement). Notwithstanding its potential benefits, the use of recording devices in a production environment can also be perceived negatively by plant personnel, and may inadvertantly influence the very "as-is" process it is trying to capture. For this reason, our approach is to utilize video-taping or live recording only after an impact-assessment has been made, and when it is clear that the use of such recordings will, in fact, deliver incremental value to a project, which could not have been attained otherwise. In our experience, and as a general rule of thumb, projects that are small in scope will not require video-recording.
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