SMED in the process Industries - Institute of Industrial Engineers
Transcript of SMED in the process Industries - Institute of Industrial Engineers
Why reduce changeover time?
Origins of SMED ~ “Necessity is the mother………”
The SMED process
SMED tools
Process plant challenges
SMED beyond product changeovers
SMED in real life
AGENDA
2MATERIAL PROTECTED BY COPYRIGHT – ALL RIGHTS RESERVED
When the production equipment is reconfigured or modified, or controlled settings are changed….
Product changeover
Product transition
Changeover
C/O
Set-up
TERMINOLOGY
3MATERIAL PROTECTED BY COPYRIGHT – ALL RIGHTS RESERVED
CHANGEOVERPRODUCT A FIRST QUALITY PRODUCT B
Getting toolsGetting replacement parts (gaskets, filters, guides)Cooling downMechanical modificationsCalibrating, adjustingHeating upDiscarding spent partsPutting tools awayGetting back to process conditionsGetting back within product specifications
CHANGEOVER ACTIVITIES
4MATERIAL PROTECTED BY COPYRIGHT – ALL RIGHTS RESERVED
Shorter changeovers reduce wasteOverproductionInventoryTimeLaborDefects, yield losses
Shorter changeovers allow faster production cycles
Faster cycles reduce inventory
Faster cycles increase production flexibility
Simpler changeovers may be safer
WHY IS CHANGEOVER TIME IMPORTANT?
5MATERIAL PROTECTED BY COPYRIGHT – ALL RIGHTS RESERVED
WHY IS CHANGEOVER TIME IMPORTANT?
A
C
B
D
EFG
H
I
JK
PRODUCTS (SPOKES)
CHANGE-OVERS
PRODUCTS (SPOKES)
CHANGE-OVERS
Faster changeovers mean shorter production cycles
Short cycles = less inventoryShort cycles = more flexibilityShort cycles = shorter lead times
6MATERIAL PROTECTED BY COPYRIGHT – ALL RIGHTS RESERVED
Toyota, circa 1950Replacing a die on large body part press = several hoursShigeo Shingo devises a method of
Examining all set-up operationsModifying the set-up processReducing time and waste
Toyota, circa 1960Replacing a die on large body part press = 15 minutes
Toyota, circa 1970Replacing a die on large body part press = 3 minutes
ORIGINS OF SMED
Shingo’s methods have become the standard for changeover reduction
Single Minutes Exchange of Dies
7MATERIAL PROTECTED BY COPYRIGHT – ALL RIGHTS RESERVED
Identify taskswhich can be external
Move external tasksoutside the changeoverwindow
SimplifyInternal tasks
PerformInternal tasksin parallel
SMED IMPROVEMENT STEPS
CHANGE OVER
CHANGE OVERPRODUCT A PRODUCT B PRODUCT C
EXTERNAL TASKS
EXTERNAL TASKS
PRODUCT ACHANGEOVER
PRODUCT BINTERNAL TASKS
EXTERNAL TASKS
EXTERNAL TASKS
PRODUCT A INTERNAL TASKS PRODUCT B
EXTERNAL TASKS
EXTERNAL TASKS
PRODUCT AINTERNAL TASKS
INTERNAL TASKSPRODUCT B
EXTERNAL TASKS
EXTERNAL TASKS
PRODUCT A INTERNAL TASKS PRODUCT B
8MATERIAL PROTECTED BY COPYRIGHT – ALL RIGHTS RESERVED
Direct observation
Video
Detailed flowchart of tasks
Activity list
Cross-functional process map
Point-to-point chart
SMED TOOLS
Roll Prep
9MATERIAL PROTECTED BY COPYRIGHT – ALL RIGHTS RESERVED
PROCESS PLANT CHANGEOVER COMPONENTS
CHANGEOVER
MANUAL TASKS
PHYSICS AND CHEMISTRY REACH EQUILIBRIUM
BEGIN PRODUCT BPRODUCT A
FIRST QUALITY PRODUCT B
FOLLOW THE MONEY
10MATERIAL PROTECTED BY COPYRIGHT – ALL RIGHTS RESERVED
Categories of Process Industry changeover
How SMED applies to them
11MATERIAL PROTECTED BY COPYRIGHT – ALL RIGHTS RESERVED
A C/O WITH ONLY MANUAL TASKS
Changing the knife positions on a slitterBetween rolls……
Loosen the knife fittingsMeasure/mark the new positionsMove the knives to the new positionsTighten the fittings
SMED possibilitiesDetailed examination of all specific steps for simplificationAre there any tasks which could be external?Could a second operator speed up the task?Consider more positive positioning mechanisms - detentsIs laser positioning of the knives feasible?
12MATERIAL PROTECTED BY COPYRIGHT – ALL RIGHTS RESERVED
Roll Slitting Machine 1
A C/O WITH ONLY MANUAL TASKS
Changing the bag size or box size on a cereal (or fertilizer, or plastic pellet …) packaging line……
Remove old bag stockClean out the pneumatic linesAdjust the bag holding fixturesPosition new bag stockRestart the line – test a few bags for fill and sealing
SMED possibilitiesDetailed examination of all specific steps for simplificationAre there any tasks which could be external?Could a second operator speed up the task?Has the product sequence been optimized to minimize material cleanouts?Could there be a complete second set of fixtures, pre-loaded with the new size stock?
13MATERIAL PROTECTED BY COPYRIGHT – ALL RIGHTS RESERVED
Changing the temperature on the bonding (heat treating) roll in a sheet manufacturing process……
Set the new temperatureWait for the roll to reach the new
temperature and stabilize
A C/O WITH CHEMICAL OR PHYSICS CHANGES
SMED possibilitiesStructured brainstorming workshop with
Mechanical engineersPhysicistsMechanicsOperators
to conceive practical techniques for more rapid heating & cooling
Roll Bonder 2
14MATERIAL PROTECTED BY COPYRIGHT – ALL RIGHTS RESERVED
Other examples……Changing the oven baking temperature in a bread plantChanging the temperature in a polymerization autoclaveChanging the raw material feed concentrations in a chemical reaction……………..Others??
A C/O WITH CHEMICAL OR PHYSICS CHANGES
15MATERIAL PROTECTED BY COPYRIGHT – ALL RIGHTS RESERVED
In the application of the photosensitive emulsion to x-ray filmsChanging to the next emulsion type……
Valve off the current emulsionRemove the coating applicator Clean the applicatorRe-attach the applicatorOpen the valve for the next emulsionRun the film – apply the new coatingAllow time for the flow to stabilize and thickness to reach uniformityTake samples to the test labOnce results are in limits, begin the next roll
A C/O WITH CHEM AND MANUAL TASKS
CHANGEOVER
MANUAL TASKS
PHYSICS AND CHEMISTRY REACH EQUILIBRIUM
BEGIN PRODUCT BPRODUCT A
FIRST QUALITY PRODUCT B
16MATERIAL PROTECTED BY COPYRIGHT – ALL RIGHTS RESERVED
Coater 1
X-ray Casting Machine 1
Roll Slitting Machine 1
Chopper 1
In the application of the photosensitive emulsion to x-ray filmsChanging to the next emulsion type……
Valve off the current emulsionRemove the coating applicator Clean the applicatorRe-attach the applicatorOpen the valve for the next emulsionRun the film – apply the new coatingAllow time for the flow to stabilize and thickness to reach uniformityTake samples to the test labOnce results are in limits, begin the next roll
A C/O WITH CHEM AND MANUAL TASKS
CHANGEOVER
MANUAL TASKS
PHYSICS AND CHEMISTRY REACH EQUILIBRIUM
BEGIN PRODUCT BPRODUCT A
FIRST QUALITY PRODUCT B
17MATERIAL PROTECTED BY COPYRIGHT – ALL RIGHTS RESERVED
MANUAL TASKS
PHYSICS AND CHEMISTRY REACH EQUILIBRIUM
Coater 1
SMED possibilitiesAnalyze the applicator removal – cleaning – replacement process
Internal External?
Simplify the process?
Purchase a 2nd applicator - have it ready to go on?
Analyze the test lab operations
Simplification
Lab lead time improvement
Structured brainstorming with coating experts and physicists – to improve coating uniformity and repeatability
A C/O WITH CHEM AND MANUAL TASKS
18MATERIAL PROTECTED BY COPYRIGHT – ALL RIGHTS RESERVED
A C/O WITH CHEM AND MANUAL TASKS
Other examplesChanging the dyeability of synthetic carpet fibersChanging the particle size in a pigment grinding – milling operation……..…….Others?
19MATERIAL PROTECTED BY COPYRIGHT – ALL RIGHTS RESERVED
The current state VSM can show where SMED will have the biggest impact
WHERE TO USE SMED
Not always the steps with the longest C/O time
The steps with long EPEI cycles
Steps with large C/O losses
20MATERIAL PROTECTED BY COPYRIGHT – ALL RIGHTS RESERVED
After changeover time has been reduced…..
Be sure to re-examine campaign length to how much reduction is possible
TAKE ADVANTAGE OF THE IMPROVEMENT
Show the improvement results on the Future State VSM
21MATERIAL PROTECTED BY COPYRIGHT – ALL RIGHTS RESERVED
Some process equipment must be taken out of serviceNot because of a product changeoverBut for a periodic overhaulSome equipment requires this every 6 months, 12 months, or 24 months
SMED BEYOND PRODUCT CHANGES
Pipes get blasted out
Tanks have residue removed
Corroded parts are replaced
Precision rolls get resurfaced
Catalyst beds get restored
Extrusion dies get cleaned
22MATERIAL PROTECTED BY COPYRIGHT – ALL RIGHTS RESERVED
Even if managed very well, these periodic shutdowns can cause all of the wastes that product changes do.
SMED BEYOND PRODUCT CHANGES
Inventory is created to maintain supply during the outageBringing tools and replacement parts to the area creates movement and transportation wasteYield loss, defect waste can occur as the process is restarted.
SMED can reduce these wastes just as it does with product changeovers
This is the primary application of SMED in many process pants
23MATERIAL PROTECTED BY COPYRIGHT – ALL RIGHTS RESERVED
SMED is very complementary with other Lean tools
5S A better organized workplace will enable faster changeovers
Visual Management A more visual workplace enables better changeoversVisual metrics help to sustain the improvements
Kaizen EventsKaizen events are a good way to conduct SMED activitiesBUT… may require more planningBUT… may require specific skillsBUT… may not be able to demonstrate results during the week
SMED SYNERGY WITH OTHER LEAN TOOLS
24MATERIAL PROTECTED BY COPYRIGHT – ALL RIGHTS RESERVED
Many books and articles use a race car pit crew as an example of changeovers done very well
Anyone who has seen a professional automobile race can appreciate the
PrecisionCoordination Purposefulness
SMED IN REAL LIFE
25MATERIAL PROTECTED BY COPYRIGHT – ALL RIGHTS RESERVED
The pit crew operation is a very strong visual image of SMED principles at work
SMED IN REAL LIFE
All internal tasks are done in parallelTechnology has been applied where appropriateEveryone understands their role, and has practiced it frequentlyAll pit stops are timedThere is an intense on-going effort to continue to reduce the time
All tasks that can be done externally are
All tasks have been thoroughly analyzed and simplified to be done as quickly as possible
26MATERIAL PROTECTED BY COPYRIGHT – ALL RIGHTS RESERVED
The pit crew operation is a very strong visual image of SMED principles at work
SMED IN REAL LIFE
All internal tasks are done in parallelTechnology has been applied where appropriateEveryone understands their role, and has practiced it frequentlyAll pit stops are timedThere is an intense on-going effort to continue to reduce the time
All tasks that can be done externally are
All tasks have been thoroughly analyzed and simplified to be done as quickly as possible
27MATERIAL PROTECTED BY COPYRIGHT – ALL RIGHTS RESERVED
Summary
28MATERIAL PROTECTED BY COPYRIGHT – ALL RIGHTS RESERVED
Long product changeover time adds a LOT of wasteDrives long campaigns, drives overproductionMakes the operation less flexible, less responsiveCreates Inventory
To attack this waste, Shigeo Shingo developed the SMED methodologyIdentify external tasks – move outside C/O windowSimplify internal tasks, do in parallel if possible
In Process operations, most of C/O time can be in getting back to specsSo SMED must identify and address this also
After SMED has been successfully doneDo it againMake sure to take advantage of the improvement
SMED can have great value applied to annual shutdowns/overhauls
Questions?
(302) 239-1667(302) 528-2700
29MATERIAL PROTECTED BY COPYRIGHT – ALL RIGHTS RESERVED