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Identify and map all the steps necessary to design, order and produce the product across the whole value stream to highlight non-value adding activity muda. Make those actions that create value flow without interruption, detours, backflows, waiting or scrap.
Only make what is pulled by the customer. Strive for perfection by continually removing successive layers of waste as they are uncovered. He used SMED to reduce the lot size of Toyota cars and the set-up time of hull assembly on a 65, ton super tanker, setting a record in shipbuilding in SMED is a concept to reduce changeover time i.
Does SMED mean changing the die in less than a minute? There is a common misconception that SMED means changing the die in 1 minute. Actually, SMED means changing the die in less than 10 minutes.
It is single digit minute exchange of dies. Running large batches is good…. We always want to run large batches of a product and not have to deal with changing over from one product to another, or from one size to another.
Click on image to enlarge. Why running large batches is harmful As a result of running large batches and producing more than what is required at the right time, we pay more in terms of downtime the eight wastes of Lean, namely defects, overproduction, waiting, non-utilized talent, transport, inventory, motion, and excessive processing; but these costs are not easily visible.
SMED increases the flexibility of a line or company to respond to customer requirements. Therefore, satisfying our customers by giving them what they want on-time and at the same time reduces our company costs as well.
SMED should not be used to run even larger batches as a result of cutting down on the set-up time. It is a total abuse of the tool. Develop and complete the external set-up checklist. Process information and storage locations.Quick Changeover & SMED are invaluable tools in the pursuit of flow.
Quick Changeover (QCO) can be achieved by the system Shigeo Shingo developed in the late ies called Single Minute Exchange of Die (SMED).
- Single Minute Exchange of Dies (SMED) - Value Stream Mapping (VSM) - Business Process Reengineering (BPR) - Quality in daily work processes (Quality at the source, poka yoke etc.) - Standard work on the shop floor (Job instructions, Standard work sheets etc.) - Establishing new system for making tenders and offers to clients.
Project. Introduction Poka-Yoke Techniques to Correct Defects + developed perhaps the most revolutionary concept in manufacturing called “Single Minute Exchange of Dies”. This concept was integrated into the JIT/ Toyota Production Dr. Shigeo Shingo’s Zero Quality Control (ZQC) techniques make use of the following engineering principles.
introduction Poka-Yoke is Japanese for mistake-proofing developed by a Japanese Industrial Engineer, Shigeo Shingo. The Practice of Poka-Yoke then arose in the Japanese manufacturing community to enhance the quality of products by preventing mistakes in the production line for achieving Zero Defects.
Single Minute Exchange of Dies, commonly known as SMED, helps with step three. Origin of SMED Dr. Shigeo Shingo is known as the father of SMED (developed in the late s) and Poka-Yoke, and is also known for developing the Just-in-Time (JIT) concept.
Analyse how poka-yoke can continuously improve the system. POKA-YOKE • Poka-yoke is a Japanese term that means “mistake-proofing”. A poka-yoke is any mechanism in a lean manufacturing process that helps an equipment operator to avoid (yokeru) mistakes (poka).