Enhancing SMED: Changeover Out of Machine Evaluation Technique to implement the duplication strategy

The present paper introduces an integrated approach to support the process engineers during the implementation of the conventional Single Minute Exchange of Dies. In particular, the proposed approach grounds on the new concept of ‘duplication strategy’, and takes advantage of an implementation tool here presented. It follows a top-down functional decomposition of machines, which helps practitioners identifying all those items impacting on the changeover process, and to propose appropriate intervention strategies. It aims at verifying the possibility of replicating entire parts of machines, fixtures and/or equipment, in order to externalise as many tasks as possible, yet carefully evaluating the cost-benefit ratio and any operational issue of the intervention. To show this novel approach, an actual implementation is hereby fully described. Finally, the results of the study are commented and proposals for future possible developments are suggested.     

Centerline-SMED integration for machine changeovers improvement in food industry

This paper demonstrates how it is possible to combine SMED with Centerlining in complex production environments with numerous changes of format, product, raw materials and tools. This research proposes a methodology involving an initial application of Centerlining and, once the machinery and the process are stable, the subsequent implementation of SMED. Furthermore, it aims to show that it is possible to achieve improved output and reduced machinery changeover time while ensuring that the effect achieved by SMED is more stable. This increases the organizational advantages with respect to the implementation of SMED without prior application of Centerlining. The most important overall conclusion is that a successful application of SMED must always be accompanied by another type of tool or technique to maximize the results of its application. And, as presented in this work, one technique that enables significant improvements to SMED is the application of Centerlining.     

Setup Time Reduction for Electronics Assembly: Combining Simple (SMED) and IT‐Based Methods

As much as 50% of effective capacity can be lost to setups in printed circuit board assembly. Shigeo Shingo showed that radical reductions in setup times are possible in metal fabrication using an approach he called “Single Minute Exchange of Dies” (SMED). We applied SMED to setups of high speed circuit board assembly tools. Its key concepts were valid in this very different industry, but while SMED typically emphasizes process simplification, we had to add modern information technology tools including wireless terminals, barcodes, and a relational database. These tools shield operators from the inherent complexity of managing thousands of unique parts and feeders. The economic value of setup reduction is rarely calculated. We estimate a reduction of key setup times by more than 80%, and direct benefits of $1.8 million per year. Total cost of the changes was approximately $350,000.