SMED快速换模英文).ppt

1、1,A STRATEGY FOR PERFORMANCE EXCELLENCE,SMED,( One Step Setup),Set-up and changeover reductions for equipment, tooling and machines.,2,Executive Overview,Participant manual,Tools Workbook,Knowledge Breakthrough,Lecture notes,Lecture notes,Performance Excellence Series Training Module Elements,3,Sess

2、ion 1.0Introduction. 4 Session 2.0Waste Management . 12 Session 3.0Setup Practices. 22 Session 4.0Traditional /Strategic Setup Approach 29 Session 5.0SMED Implementation Planning. 34 Element 5.1 Implementation Team 36 Element 5.2Implementation Plan. 37 Element 5.3Communication Plan. 38 Element 5.4Tr

3、aining Plan. 40 Element 5.5One Step Setup. 42 Element 5.5.1Separate Internal from External Setup 44 Element 5.5.2Integrating Internal into External Setup. 49 Element 5.5.3 Reducing Setup Processing Time. 63 Element 5.5.4Optimizing Setup Processes. 92 Element 5.6Verification & Standardization 95 Sess

4、ion 6.0Summary 105,Table of Contents Knowledge Breakthrough,SMED,4,SMED is Continuous Improvement,It is a customer driven requirement. Customers are demanding: Product and service diversity Lower costs Higher reliability and quality. In essence organizations need to become leaner ! So organizations

5、must: Produce smaller lots, more frequently. Expand the scope and diversity of products and services. Reduce quality defects.,5,Ultimately, SMED focuses on reducing changeover and set-up times, thus enabling organizations to:,Produce smaller lots of products and services more frequently ! Develop a

6、broader scope of products and services ! Reduce quality defects towards zero !,Meet Customers Expectations !,6,What Does Set-up/changeover reduction mean for my business?,Increased customer service levels and profits ! Via Waste Elimination resulting in: Reduced Lead Times-Faster Delivery Zero Inven

7、tories-Reduced Working Capital Improved Quality Improved Safety Smaller lots of products-flexibility Diversified Product & Service Options,7,To eliminate the wastes that result from “uncontrolled” processes increasing inventories and lead times. To gain control on equipment, material & inventory. Ap

8、ply Control Techniques to Eliminate Erosion of Improvements. Standardize Improvements for Maintenance of Critical Set-up Parameters.,Look Familiar?,Why SMED ?,8,MajorCPI Tools(6s) Kaizen LeanDescription Cp/Cpk 4Process capability assessment DOE 4Design of experiments SPC 4Process control based on st

9、atistics and data analysis FMEA 4Risk assessment tool Regression 4Correlate effect one variable has on another Process Map 4 4 4Map process steps to communicate and identify opportunities 5 whys /2 hows 4 4 4 Determination methods for root cause discovery Pareto 4 4 4Column chart ranking items highe

10、st to lowest Fishbone 4 4 4Cause / Effect Diagram 5S 44Elimination waste Visual Mgmt 4 4 4Emphasis on visual techniques to manage process Poka-Yoke 4 4Error proofing techniques Spaghetti Chart 4 4 Kanban 4 4Material storage technique used to control process Takt Time 4 4Determine pace or beat of a p

11、rocess Std Work 4 4Evaluate tasks done during a process SMED 4 4Single minute exchange of dies - Quick machine set up TPM 4Integrate maintenance strategy with process Cellular Flow 4Reduce inventory & cycle time through process layout and pull production techniques,Expand Process Improvement Program

12、 to Utilize Kaizen Tool Kit,Tool Kit Comparison,9,Identify what types of internal and external setup times are involved in the following pictures.,Picture A: Wire Cutting Machine,Picture B: Metal Stamping Machine,10,Identify what types of internal and external setup & times are involved in the follo

13、wing pictures.,Picture A: Wire Cutting Machine,Picture B: Metal Stamping Machine,_,_,Setup Type,Setup Type,Time ( Min),Time ( Min),Think Break,11,Internal External Setup,Classify Three items under each item category.,External,Internal,_,_,Which items would you convert from internal to external Setup

14、 ? _ Why? _,Think Break,12,Traditional Setup Practices,Material movement occurs after the machine is turned off.,Detection of defects or missing equipment is noticed which the machine is running.,Defective tooling,fixtures, setup instruments are noticed after the machine is turned on.,Completed prod

15、ucts are transferred to next operation. Raw material is moved after the machine is stopped.,Setup tooling delivered after the changeover has begun. Defective product identified after internal setup has begun.,The operator notices that equipment is missing after internal setup has begun.,13,Preparati

16、on - Ensures that all the tools are working properly and are in the right location. Mounting & Extraction - Involves the removal of the tooling after the production lot is completed and the placement of the new tooling before the next production lot. Establishing Control Settings - Setting all the p

17、rocess control settings prior to the production run. Inclusive of calibrations and measurements needed to make the machine, tooling operate effectively. First Run Capability - This includes the necessary adjustments( re-calibrations, additional measurements) required after the first trial pieces are

18、 produced. Setup Improvement- The time after processing during which the tooling, machinery is cleaned, identified, and tested for functionality prior to storage.,5 “Traditional”Setup Steps Defined,14,“Traditional”Setup Resource Consumption Analysis,15,Examples of wastes in a traditional setup !,Wha

19、t kind of “setup wastes” can you identify in this pictures ? _,Think Break,16,Separate Internal from External Setup,Optimizing Setup Processes,Integrate Internal into External Setup,Reduction of Setup Processes,One Step Setup Implementation Plan,Progressive Enhancements,Step 2 Develop Specific Imple

20、mentation Plan,Step 3 Develop Communication Plan,Step 4 Develop One Step Setup Training Plan,Step 5 Implement One Step Set-up,Step 6 Verification / Standardization,Step 1 Develop One Step Setup Implementation Team,17,Phase 2,Combining equipment functionality,Involves standardizing the equipment ( pa

21、rts, tooling, processes) based on commonality between setups to reduce the number of setup steps and cycle times.,The common setup parts were identified and replaced with this jig/holder combination.,Notice how different quantities of the same part can be setup with the same fixture. Also, these setups