Single Minute Exchange of Die or SMED can dramatically increase the efficiency of a company. This guide will help you understand the goals, benefits, and procedures of SMED.

What is SMED?

Single Minute Exchange of Die is a strategic process aimed at reducing setup and production time bringing it under 10 minutes. First introduced as a lean management tool in 1969 by Shigeo Shingo, SMED is now being used in various industries to reduce changeover times of a series.

Goals of SMED

Take a look at some goals of SMED:

• Reduced changeover times
• Increased productivity
• Reduced downtime
• Cost-effectiveness
• Streamlined startup processes
• Improved consistency and quality

Benefits of SMED

The advantages of SMED can be divided into different categories. Here’s a brief overview:

Operational Benefits

SMED helps minimize setup times, allowing for faster production changeovers and increased productivity. When setup times are reduced, organizations can produce more products in the same amount of time. They can quickly respond to customer requirements and update production schedules. Operational benefits also reduce downtime, leading to continuous production.

Financial Benefits

Due to reduced setup times, organizations can take on more orders and generate additional revenue. This can reduce the cost of equipment and resources. Organizations that incorporate SMED often get regular maintenance, extending equipment lifespan.

Environmental Benefits

SMED optimizes production, reducing energy waste. This is especially useful for lean manufacturing practices. When companies focus on better resource utilization and reduced carbon footprint, they contribute to the betterment of their environment.

Employee Benefits

SMED promotes employee engagement and motivation through standardized processes. Moreover, a simplified setup reduces physical and mental strain. This can lead to increased job satisfaction and productivity. An important part of SMED is employee training and development.

How to Implement SMED

SMED requires a structured approach to minimize setup times and maximize efficiency. Here’s how you can do it:

Need Identification

The first step is to determine the equipment and processes with the longest setup times. You need to conduct a thorough analysis to determine production times and consequent volumes.

Separate Internal and External Setup Activities

Classify setup activities as internal (performed during machine downtime) or external (performed while the machine is running). Move external activities to internal setup phases.

Streamline Internal Setup Processes

Simplify and standardize internal setup procedures. Aim to eliminate all unnecessary steps and motions.

Convert Internal Setup to External Setup

Prepare setup materials and tools in advance and determine which steps can be performed while the machine is still running.

Standardize Procedures

Develop standardized setup instructions. You can create visual aids and training materials to establish a standard quality guide.

Train Employees

Train employees on new setup procedures. Encourage employee involvement and feedback. Make sure you recognize and reward reduced setup times.

Monitor and Improve

Keep an eye on the subtle increase in production and highlight areas where SMED doesn’t seem to make any changes.

Expand SMED to Other Areas

SMED is not limited to production or equipment. Best practices can be helpful for other departments.