SMEDTPM之快速换模

SMED-QuickChangeover2•Introduction•BackgroundandHistory•ComponentsandImplementation–ChangeoverandChangeoverTime–TraditionalSetup–SMED(SingleMinuteExchangeofDies)–SMEDProcessSteps–IdeasforImprovement•KnowledgeCheck3•QuickChangeoverisoneofthecoreconceptsofleanmanufacturing•Arapidandefficientwayofconvertingaprocessfromrunningthecurrentproducttorunningthenextproduct•Alsoknownas“singleminuteexchangeofdies”(SMED)–derivedfromthedesiretochangeoveranyprocesswithinminutesinsteadofhours•Reducesthewasteofinventorybycreatingshorterproductionrunsthatbetteralignwithcustomerdemand4•Developedinthelate1950’sandearly1960’sbyShigeoShingo,chiefengineerofToyota•LandcostsinJapanwereveryhigh,thereforeitwasnotfeasibletostorelargeinventoriesofvehicles•QuickChangeoverprovidedasolutiontotheeconomiclotsizeproblemoftraditionalmanufacturing,whichpromotedlargelotsizes5•ChangeoverandChangeoverTime•TraditionalSetup•SMED(SingleMinuteExchangeofDies)•SMEDProcessSteps•IdeasforImprovement6•Definition:–Changeoveristhetotalprocessofconvertingamachineorlinefromrunningoneproducttoanother7•Definition:–Changeovertimeisthetotalelapsedtimebetweenthelastunitofgoodproductionofthepreviousrun,atnormallineefficiency,tothefirstunitofgoodproductionofthesucceedingrun,atfulllineefficiency.8•Objective:–Reducechangeoverfromhourstosingleminutes9•It’sallbeensaidbefore…–“Beserious…”–“Can’treallyhappen…”–“Whatareyousmoking…”–“Ouroperationisunique…”–“That’sonlyinlow-techmoldingorstamping…”–“Wecan’tmoveanyfaster…”–“We’realreadythebestatwhatwedo…”10•Typicalchangeover:1–2hours11Typicalchangeover:minutes...Orseconds12•3000-tonsheetmetalstampingpress–Before:4hours–After:3minutes–Improvement:98.7%,orafactorof80–Nowthesamepresscanmakemultipleparts(hoodsanddoorsinthiscase)fortheCamry,onlywhatisneededforthenexthourofproduction.•400-tonLIMmoldingpresswith16-cavitytool–Before:3hours–After:18minutes–Increaseineffectivecapacityequalto5,184additionalparts13CompanyMachineBeforeimprovementAfterimprovementRed’nTManufacturing180tsingleshotpress4hrs4min18sec98%SMetals1100tsingleshotpress40min2min26sec94%HPress130tsingleshotpress50min48sec98%TTIndustries150ozinjectionmouldingm/c1hr10min7min36sec89%ExpandedMetalCo.4’6”lathpress4hr30min11min(NOTSMED)96%SEngineeringMachiningCentre139mins59min29sec57%*AMBottlersBottlingplant32min43sec23min33sec28%*EFinishingPaintPlant56min26sec23min12sec59%*CompanyMachineBeforeimprovementAfterimprovementRed’nTManufacturing180tsingleshotpress4hrs4min18sec98%SMetals1100tsingleshotpress40min2min26sec94%HPress130tsingleshotpress50min48sec98%TTIndustries150ozinjectionmouldingm/c1hr10min7min36sec89%ExpandedMetalCo.4’6”lathpress4hr30min11min(NOTSMED)96%SEngineeringMachiningCentre139mins59min29sec57%*AMBottlersBottlingplant32min43sec23min33sec28%*EFinishingPaintPlant56min26sec23min12sec59%*Ref1:ModernApproachestomanufacturingimprovement–theShingoSystem,ShigeoShingo,ISBN:091529964x*AfteroneSMEDexercise14•Betterquality–Verydefinedsetupprocesses•Lowercost–Lessscrapandinventory•Betterflexibility–Rapidlychangefromproducttoproduct•Betterworkerutilization–Lesstimespentonsetuporwaitingfortheruntostart•Shorterleadtimeandmorecapacity•Lessprocessvariability15•Itisacustomer-drivenrequirement.Customersaredemanding:–Productandservicediversity–Lowercosts–Higherreliabilityandquality.•Soorganizationsmust:–Producesmallerlots,morefrequently.–Expandthescopeanddiversityofproducts–Reducequalitydefects.16•Setupisgivenandfixed•Therefore,–Usehighlyskilledsetuppersonnel–Minimizeproductvariety–Combinelots–Makelargebatches17•SetupsCANbeimproved!•SmalllotproductionREQUIRESshortsetups•Setuptimereductionof90%andmoreiscommon181.Preparation–Ensuresthatallthetoolsareworkingproperlyandareintherightlocation.2.Extraction–Theremovalofthetooling,rawmaterial,andsupportequipmentaftertheproductionlotiscompleted.3.Mounting–Theplacementofthenewtool,supportequipment,andrawmaterialbeforethenextproductionlot.4.EstablishingControlSettings–Settingalltheprocesscontrolsettingspriortotheproductionrun.5.FirstRunCapability–Thisincludesthenecessaryadjustmentsrequiredafterthefirsttrialpiecesareproduced.6.SetupImprovement–Thetimeafterprocessingduringwhichthetooling,machineryiscleaned,identified,andtestedforfunctionalitypriortostorage.19•Step1–Observeandrecord.•Step2–Separateinternalandexternalactivities.•Step3–Convertinternalactivitiestoexternalactivities.•Step4–Streamlineallactivities.•Step5–Documentinternalandexternalprocedures.20•Team-work–Recorder•Recordoverallduration(fromlastproducttofirstgoodproduct).•Videorecordersworkverywell•Describethechange(fromwhattowhat?).–Timers•Timeeachstep–Factcollectors•Breakdownthestepsintoactions–asmuchdetailaspossible.•Usealaymantoaskuninformedquestions–challengethe“acceptednorm”.21•Timers.–Aimtohave10-20stepsforeachchangeover.–Recordtheelapsedtime.Calculatethesteptimelater.StepDescriptionTimeBarChartElapsedStep1Removeguards3min42sec3min42sec2Loosenbottombolts12min12sec8min30sec3Lowerram19min29sec7min17sec4Loosentopbolts31min13sec11min44secStepDescriptionTimeBarChartElapsedStep1Removeg