what is smed? · single minute exchange of dies: smed is a problem solving tool used to decrease...

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What Is SMED?

Single Minute Exchange of Dies:

SMED is a problem solving tool used to

decrease the amount of set-up time

required from the last Good piece

produced to the first Good piece

produced

Precursor: 5s - completed and

standardized weeks in advanced

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WHY IMPLEMENT SMED

•Reduces the need for inventory,

•Provides more flexibility and capacity,

•Done correctly, improves safety

•Enables us to better serve our customer

•Standard processes provide for better and

more consistent Quality.

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Set-up Reduction – Gross adjustment Go

tools before fine alignment

Before

After

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Set-up Reduction – Pick vs. Calculate Gears

Before

After

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Set-up Reduction – Gross adjustment tools

before fine alignment

COLLAR SETTINGS

LAP

5 5 1/2 6 7

13 33 5/8 33 1/8 32 5/8 31 5/8

13 1/2 33 3/8 32 7/8 32 3/8 31 3/8

14 33 1/8 32 5/8 32 1/8 31 1/8

14 1/2 32 7/8 32 3/8 31 7/8 30 7/8

15 32 5/8 32 1/8 31 5/8 30 5/8

15 1/2 32 3/8 31 7/8 31 3/8 30 3/8

FA

CE

16 32 1/8 31 5/8 31 1/8 30 1/8

16 1/2 31 7/8 31 3/8 30 7/8 29 7/8

17 31 5/8 31 1/8 30 5/8 29 5/8

17 1/2 31 3/8 30 7/8 30 3/8 29 3/8

18 31 1/8 30 5/8 30 1/8 29 1/8

18 1/2 30 7/8 30 3/8 29 7/8 28 7/8

19 30 5/8 30 1/8 29 5/8 28 5/8

19 1/2 30 3/8 29 7/8 29 3/8 28 3/8

20 30 1/8 29 5/8 29 1/8 28 1/8

20 1/2 29 7/8 29 3/8 28 7/8 27 7/8

21 29 5/8 29 1/8 28 5/8 27 5/8

21 1/2 29 3/8 28 7/8 28 3/8 27 3/8

22 29 1/8 28 5/8 28 1/8 27 1/8

22 1/2 28 7/8 28 3/8 27 7/8 26 7/8

23 28 5/8 28 1/8 27 5/8 26 5/8

23 1/2 28 3/8 27 7/8 27 3/8 26 3/8

24 28 1/8 27 5/8 27 1/8 26 1/8 6

Set-up Reduction – Measurement Reference Matrix

Set-up Reduction – Organized & Accessible Tools

Order Step Time 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100

101

102

103

104

105

106

107

108

109

110

111

112

113

114

115

116

117

118

119

120

121

122

123

124

125

126

127

128

129

130

131

132

133

134

135

136

137

138

139

140

141

142

143

144

145

146

147

148

149

150

151

152

153

154

155

156

157

158

159

160

161

162

163

164

165

166

167

168

169

170

171

172

173

174

175

176

177

178

179

180

181

182

183

184

185

186

187

188

189

190

191

192

193

194

195

196

197

198

199

200

201

202

203

204

205

206

207

208

209

210

211

212

213

214

215

216

217

218

219

220

221

222

Operator

1 release snatcher 1

2 Set Table & Former 7

3 Lockout 1

4 change bars 15

5 change spots 6

6 change Perf rollers 5

7 change glue pans 5

8 pull paper 5

9 Lineout 5

10 set donuts 3

11 set eye registration 3

12 set cutoff 2

13 set selector drum 2

Utility

1 finish pallet 5

2 Lockout 1

3 change gear 5

4 set spot and bar dials (length) 5

5 change bars 8

6 change spots 5

7 change perf rollers 5

8 change glue 5

9 pull paper 5

10 set knife dials 5

11 take slack out 3

12 position/set spots 2

13 takeaway scrap 2

Asst

1 Disengage Perf rollers 1

2 replace paper 20

3 prep inline(cylinders, ink,) 15

4 pull paper 5

5 take slack out 3

6 set edge aligners 2

7 strike inline 2

8 move seam wheels & position eye sens. 2

9 engage perf rollers 1

10 set bite 1

Kaizen Results Set-up Reduction – Distribute Labor Supporting Common Tasks

Kaizen Results

• Pre-event set-up reduction = 2.5 Hours o 2 ply - 2 ply change with tail printing

• Post-event set-up reduction = 45 minutes. o 2 ply - 2 ply change with tail printing

• Pre-event set-up reduction > 2.5 Hours o 3 ply - 3 ply change with tail printing (50lb to 40lb)

• Post-event set-up reduction = 1.5 Hours

o 3 ply - 3 ply change with tail printing (50lb to 40lb)