On October 21^st, 2009 our Monthly Strategic Interest Group Meeting was held at Softub Canada in Sudbury.  The topic for this month was quick changeovers, / set up reduction or what is commonly referred to  SMED…Single Minute Exchange of dies.  The discussion revolved around the reason for pursuing quick set ups to begin with.  It was pointed out that it was extremely important to get the main stake holders involved in any activity in the order of set up reduction.  The main points that were discussed were:

Definititions of a Set up:

·         Set-up Time:  The elapsed downtime between the last GOOD production pieces of Part A and the first GOOD production piece of Part B.

·         Internal Set-up:  That part of the set-up which must be done while the machine is off.

·         External Set-up:  That part of the set-up which can be done while the machine is on.

·         The measurement should also include all activities even after the first good part, if such activities (i.e. paperwork, inspection) result in further:  a.  Stoppage of process flow, and  b.  Are related to changeover

Benefits:

•          Process Becomes More Flexible To Meet Customer Requirements

•          Improved Quality

•          Increased Productivity

•          Improved Throughput

•          Increased Capacity

•          Smaller Lot Sizes

•          Decreased Leadtime

•          Allows For Reduction Of Work-In-Process

Set-Up Reductions Initially Occur In The Order of 50-75% With Little Capital Expenditure (Good Housekeeping, Organization, And Discipline).

Reductions of 90-95% Usually Requires A Large Investment For Redesigned Tooling, Job Setter Tools, And Transport Equipment

Understand the Baseline:  Create a baseline the way it is done now.

Set-up Reduction Steps:

Step 1:  Move internal set-up activities to external, doing as much as possible with the machine running.

Step 2:  Modify equipment, tools, and   methods for quick exchange during internal set-up.

Step 3:  Eliminate adjustments.

It was also discussed the importance of putting together teams to address lengthy and costly changeovers.  Results are better when a crossfunctional team is put together to tackle the changeover.  Even involving front office staff that has no experience with changeovers can benefit the team.  The importance of having a good Total Productive Maintenance Program is very important to the succss of a Set up Reduction Workshop.  You need to create a System of Activities in Which All Employees Work To Improve Up-Time And Quality Of Output & Reduce Maintenance Costs Through The Continuous Improvement Of Equipment Operation.  This includes: Preventive & Predictive Scheduled Maintenance Programs.

I would like to take this opportunity to thank Softub Canada for hosting this event.