SMED Internal and External Steps
changeover reduction continuous improvement process quick changeover smed
In continuation of our previous blog about SMED. Here are Steps #3 and #4 that can be used to dramatically reduce changeover times on your production machines.
(If you haven't read our article called Using SMED to Reduce Changeover Times, check it out and this article will all make a lot more sense!)
STEP 3: Separate Internal from External Steps
An internal step of the changeover requires that the machine be shutdown to complete that step of the changeover. An example of this includes changing a die or a machine part. An external step of the changeover can be completed while the machine is in production.
An example of this includes fetching a wrench. A video recording is a good tool to use because you can take note every time the set-up technician walks out of the camera view – whenever they do, they’re probably doing an external step of the set-up which can be done in advance. In this phase of the project, you want to start bringing tools in closer to the operator. Hang them as close as possible to the point of use. Inspection gages can be moved closer to the set-up process too, but there may be some exceptions if inspection equipment is too large or shared by others and can’t be moved closer. Typically, just removing the external steps from the set-up will yield a 25-50% reduction in machine changeover downtime.
STEP 4: Convert Internal to External
In this step you and your SMED Team are looking for process steps that are currently internal to the changeover process but have the potential to become external. This is different than just separating the internal elements from the external. Here, the changeover element is indeed internal and can’t be done with the machine in production mode, but sometimes you can redesign the step and make it external to the set-up.
For example, let’s say you have many components in one machine section that need to be
removed in order for new parts to be installed. In this case an improvement might be to changeout a larger sub-assembly using quick-change methods and then changeout the smaller components offline when the machine is in operation again running the other product. In this step of SMED, you’re trying to remove internal steps from the changeover by doing as much prep work ahead of time and offline. This may require you to purchase some extra, preassembled machine components, but the payback is well worth it.
Are you interested in exploring more continuous improvement tools? Checkout Tools for the Trenches!
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