Why use it: To minimize machine downtime due to set-up changeover. The advantages of a quick changeover are:

• Allows smaller economic lot sizes
• Ability to produce a greater variety of parts
• Reduces in process inventory
• Reduces lead times
• Minimizes machine downtime

Where to use it: For equipment that requires quick turn around times in a lean manufacturing enviroment.

When to use it: SMED changes the assumption that set ups can be done quickly, they can be done as often as needed. This means companies can make products in smaller lots, which has many advantages:

• Flexibility: companies can meet changing customer needs without the expense excess inventory.
• Quicker delivery: small lot production means fewer customers waiting time.
• Better Quality: less inventory storage means fewer storage related defects. SMED also lowers defects by reducing Set up errors and eliminating trial runs of the new products.
• Higher productivity: Shorter changeovers reduce down time, which means a higher equipment productivity rate.

How to use it: Shigeo Shingo recognises eight techniques that should be considered in implementing SMED.

1. Separate internal from external setup operations
2. Convert internal to external setup
3. Standardise function, not shape
4. Use functional clamps or eliminate fasteners altogether
5. Use intermediate jigs
6. Adopt parallel operations (see image below)
7. Eliminate adjustments
8. Mechanization

Name Format Preview (Click to enlarge)   SMED Instructions Adobe PDF Format   Set up time Analysis Microsoft Excel Format   Set up time Analysis Completed Example Microsoft Excel Format   Changeover Analysis Microsoft Excel Format

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