Single-Minute Exchange of Die (SMED)Quick Changeover (QCO)

Question 1

SMED

Answer 1

Single-Minute Exchange of Die

Question 2

QCO

Answer 2

Quick Changeover

Question 3

Process Defined

Answer 3

Start:
1)Form and train team (PST)
2) Videotape the set-up activity
3)Classify activities as external or internal
4)Eliminate external downtime
5) Convert internal to external set up
6) Study internal setup steps to develop the best method
7)Identify adjustment elimination opportunities
8) Provide training to the employees that perform the set up.
9)Time reduction goals met

END

Question 4

Form and train team (PST)

Answer 4

*It should be a team effort!

1) Technicians (bring in available peers)
2)Operators (might include neighbors)
3) Engineers (must understand the process)
4)Supervisors (must be aware to pull in others)

*Probably, those operators focused on the process might not participate from the beginning. When ready, they should!

Question 5

Videotape the set-up activity

Answer 5

a) Videotaping what happens during the changeover activity is critical to study the video and identify opportunities.

b) We need to distinguish between external and internal changeover activities.

Question 6

Classify activities as external or internal

Answer 6

1) External – activities that can occur while the machine is in operation.

2) Internal – activities that only occur when the machine is stopped.

Question 7

Eliminate external downtime

Answer 7

*Do external activities while the equipment is dedicated to the previous product

Question 8

Convert internal to external set up

Answer 8

Modify machine, eliminate threads

Question 9

Study internal set ups steps to develop the best method

Answer 9

identify and group the tools needed for stages of the set up.

Question 10

Identify adjustments elimination opportunities

Answer 10

*fixed positioning, preset tooling, standard closure space

Question 12

Provide training to the employees

Answer 12

*Using the best method until they become skilled

Question 13

Basic definitions

Answer 13

*Additional people should be brought in to speed up the activities of the changeover!

*Notice that the whole process must be repeated until the desired reduction is achieved.

Question 14

Layout concerns

Answer 14

*Where are the paperwork, tools and spare parts needed for the changeover located? Relocate all those as close as possible!

*Imagine a heart surgeon; how close should he/she be from the patient?

Question 15

Housekeeping & organization (5S)

Answer 15

*How well organized are the tools?

*A location for each tool and all tools in their defined location!

Question 16

5S

Answer 16

1)Sort
2)Set in Order
3) Shine
4)Standardize
5)Sustain

Question 17

Sort (5s)

Answer 17

Eliminate unnecessary items and prioritize essential tools and materials

Question 18

Set in order 5s

Answer 18

Organize and arrange essential items for easy access and visual management

Question 19

Shine 5s

Answer 19

Clean and maintain the workspace to ensure a safe and efficient environment

Question 20

Standardize 5s

Answer 20

Establish standardized procedures and practices to sustain the improvements made in the first three S’s

Question 21

Sustain 5s

Answer 21

Instill a culture of continuous improvement and long term adherence to the 5s principles