SMEDTPM之快速换模.ppt

SMED QuickChangeover Contents Introduction BackgroundandHistory ComponentsandImplementationChangeoverandChangeoverTimeTraditionalSetupSMED SingleMinuteExchangeofDies SMEDProcessStepsIdeasforImprovement KnowledgeCheck Introduction QuickChangeoverisoneofthecoreconceptsofleanmanufacturing Arapidandefficientwayofconvertingaprocessfromrunningthecurrentproducttorunningthenextproduct Alsoknownas singleminuteexchangeofdies SMED derivedfromthedesiretochangeoveranyprocesswithinminutesinsteadofhours Reducesthewasteofinventorybycreatingshorterproductionrunsthatbetteralignwithcustomerdemand BackgroundandHistory Developedinthelate1950 sandearly1960 sbyShigeoShingo chiefengineerofToyota LandcostsinJapanwereveryhigh thereforeitwasnotfeasibletostorelargeinventoriesofvehicles QuickChangeoverprovidedasolutiontotheeconomiclotsizeproblemoftraditionalmanufacturing whichpromotedlargelotsizes ComponentsandImplementation ChangeoverandChangeoverTime TraditionalSetup SMED SingleMinuteExchangeofDies SMEDProcessSteps IdeasforImprovement ChangeoverDefined Definition Changeoveristhetotalprocessofconvertingamachineorlinefromrunningoneproducttoanother ChangeoverTimeDefined Definition Changeovertimeisthetotalelapsedtimebetweenthelastunitofgoodproductionofthepreviousrun atnormallineefficiency tothefirstunitofgoodproductionofthesucceedingrun atfulllineefficiency TheObjective Objective Reducechangeoverfromhourstosingleminutes TimeOuttoRollYourEyes It sallbeensaidbefore Beserious Can treallyhappen Whatareyousmoking Ouroperationisunique That sonlyinlow techmoldingorstamping Wecan tmoveanyfaster We realreadythebestatwhatwedo BeforeSMED Typicalchangeover 1 2hours AfterSMED Typicalchangeover minutes Orseconds RealWorldExamples 3000 tonsheetmetalstampingpress Before 4hours After 3minutes Improvement 98 7 orafactorof80 Nowthesamepresscanmakemultipleparts hoodsanddoorsinthiscase fortheCamry onlywhatisneededforthenexthourofproduction 400 tonLIMmoldingpresswith16 cavitytool Before 3hours After 18minutes Increaseineffectivecapacityequalto5 184additionalparts MoreExamples BenefitsofSetupReduction BetterqualityVerydefinedsetupprocesses LowercostLessscrapandinventory BetterflexibilityRapidlychangefromproducttoproduct BetterworkerutilizationLesstimespentonsetuporwaitingfortheruntostart Shorterleadtimeandmorecapacity Lessprocessvariability SMEDisContinuousImprovement Itisacustomer drivenrequirement Customersaredemanding ProductandservicediversityLowercostsHigherreliabilityandquality Soorganizationsmust Producesmallerlots morefrequently ExpandthescopeanddiversityofproductsReducequalitydefects Traditionalapproach Setupisgivenandfixed Therefore Usehighlyskilledsetuppersonnel Minimizeproductvariety Combinelots Makelargebatches Anotherway SetupsCANbeimproved SmalllotproductionREQUIRESshortsetups Setuptimereductionof90 andmoreiscommon 6 Traditional SetupSteps PreparationEnsuresthatallthetoolsareworkingproperlyandareintherightlocation ExtractionTheremovalofthetooling rawmaterial andsupportequipmentaftertheproductionlotiscompleted MountingTheplacementofthenewtool supportequipment andrawmaterialbeforethenextproductionlot EstablishingControlSettingsSettingalltheprocesscontrolsettingspriortotheproductionrun FirstRunCapabilityThisincludesthenecessaryadjustmentsrequiredafterthefirsttrialpiecesareproduced SetupImprovementThetimeafterprocessingduringwhichthetooling machineryiscleaned identified andtestedforfunctionalitypriortostorage TheSMEDProcess Step1 Observeandrecord Step2 Separateinternalandexternalactivities Step3 Convertinternalactivitiestoexternalactivities Step4 Streamlineallactivities Step5 Documentinternalandexternalprocedures Step1 ObserveandRecord Team work RecorderRecordoverallduration fromlastproducttofirstgoodproduct VideorecordersworkverywellDescribethechange fromwhattowhat TimersTimeeachstep FactcollectorsBreakdownthestepsintoactions asmuchdetailaspossible Usealaymantoaskuninformedquestions challengethe acceptednorm Step1 Timers Aimtohave10 20stepsforeachchangeover Recordtheelapsedtime Calculatethesteptimelater Step1 Factcollectors Haveanumberoffactcollectorstoensureelementsarenotmissed OnefactperPost it writeclearly beconcise Recordeverything E g Forthe removeguards step factcollectorsmayrecordthefollowingelements WalktocontrolpanelSwitchmachineoffWaitforflywheeltostopGetspannerfromtoolboxRemove3hexboltsGetAllenkeyRemove5AllenboltsRemoveguardWalktorearofmachinePlaceguardonthefloorWalktofrontofmachine Step2 Separateinternalandexternalactivities Internalset upactivities Elementsinthechangeoverwhichcanonlybedonewhenthemachineisstopped Externalset upactivities Elementsthatcanbeperformedwhenthemachineisrunning Step3 Convertinternaltoexternal Studyeachinternalstepandaskifitcouldbeexternal Commonissues Diesinremotestorageracks Spannersnotavailable Rawmaterialchecks Liftingequipmentnotavailable Askwhytheremaininginternalstepscan tbeexternal Re examinethetruefunctionofeachstep Commonissues Colddies usingmaterialtoheatthedies Norecordofsettings Step4 Streamlineallactivities Analyzetheactivity anddiscussallpossiblewaysofimprovingthestep Studytheexternalactivitiesaswellastheinternalactivities Commonissues Fastenings Areboltsneeded Ifsorememberthatonlythelastturntightensanutorbolt Standardizeboltheads Standardizedieheights Equipmentandmaterialavailabilityandaccessibility Step5 Documenttheprocedures Writedownthenewinternalandexternalprocedures Fillinanactionsheettoensurethatthenewprocedurescanbeachieved Reviewthewholeactivitytodetermine Whatwentwell Whatwentbadly andchangesthattheteamwouldmakebeforethenextSMEDactivity Non ManufacturingExample DirectoryinquiriesinNewYorkhandles5 5millioncallsperdayatanaveragetimeof22secondspercall Changedtoasking Directoryinquiries whatlisting insteadof Directoryinquiries whatlistingplease NewYorkersoftenbrokeintothe please withtheirrequestanyway Reducedpeakcallcenterrequirementsfrom87operatorsto72operators Non ManufacturingExample cont AcalltoNYdirectoryinquiriesisnolongerarealtimeexperience Digitizedresponsessaved5secondsinthe1980 s Nowyourrequestisrecordedanddeliveredtothenextavailableoperator whileyouwerespeakinghewashelpingapreviouscustomer Therecordingisprocessedthroughacomputerprogramwhichremovedallofthepausesorsilencesandthe UhmsandAhs Thesoftwarethenspeedsuptherecordingby20 Peakoperatorrequirementsdroppedbyanother23 Priorities Eliminateallunnecessaryelementsofchangeover Externalizeallpossibleelements Simplifywhatremains Measure measure measure IdeasforImprovement Thefollowingslideshaveseveralpotentialareasforimprovement Combiningequipmentfunctionality Involvesstandardizingtheequipment parts tooling processes basedoncommonalitybetweensetupstoreducethenumberofsetupstepsandcycletimes Noticehowdifferentquantitiesofthesamepartcanbesetupwiththesamefixture Also thesesetupscanoccurwhilethemachineisrunning Thecommonsetuppartswereidentifiedandreplacedwiththisjig holdercombination Byusingthesefixtures thepartsareautomaticallycenteredandadjustedforheightandflatnessasapartofExternalsetup notInternalsetup Wasteassociatedwithfinding replacing motion Toolingsuppliesareclearlylabeled Toolingsuppliesareneatlyassignedauniquelocation OneStepFastening Boltattachmentsrequires32completeturnsforeachboltorscrew 1foreachthread tofastenthisboltanddietoamachine Thisclampattachmentrequiresonesteptoattachthedietoamachine Thismagneticclampattachmentrequiresonesteptoattachthedietoa3000tonpressmachine CommonProblemsSolved Problem onlythelastturntightensanutorbolt andthefirstoneloosensit Solution1 Key holes CommonProblemsSolved Problem onlythelastturnofanutorbolttightensitandonlythefirstonethatloosensit Solution2 SplitThreadMethod Threegroovescutintomaleandfemalethreads Boltinsertedbyaligningthegroovesandslidingintoposition Bolttightenedbyaone thirdturn Note theboltneedstobelongertopreservetheareaofeffectivefriction CommonProblemsSolved Problem Diesaredifferentheights operatorshavetochangetheclampingbolts Solution CommonProblemsSolved Problem Waitingfortoolingtoreachelevatedtemperatures Solutions Pre heatovens electricorsteamheating Usethecoolantwaterfromthemachinetopre heatthedies Useatransferjigwhichwillallowtheelectricalandcoolantconnectionstobemadeoff lineandtobringthedietorunningtemperature Productdesign Pre stagedparts Cleanability Flushfastenersspeedcleaning Quickcha