Ganesh R Kumar

SMED changeovers to be performed as below. 1. Select a changeover process for the study - bottle neck process (based on internal or customer oriented priorities) 2. Videotape the entire activity of current changeover process - approved video camera is preferred (with permission) 3. Document the current changeover process - Please use a element tracker sheet for observation/recording the facts 4. Display the video & analyze the entire activity of changeover processes - Record the internal & external elements and associated time for detailed understanding - Generally 40 mins video analysis takes 15-18 hrs for understanding 5. Identify the total no of activities for the 40 mins & then Re-design the changeover process based on the critical elements - Process involves converting internal elements to external & Sequential elements to parallel elements - Standardize the equipment & tooling, move to one touch attachments/bolts/interlocking grooves/fixtures/clamps, eliminate adjustments - Recommended to use ECRS approach (eliminate, combine, re-arrange & simplify) 6. Prepare Improvement actions list with responsibility/target time for implementation - Implement & Improve the changeover process 7. Compare the before vs after improvement for monitoring purpose & for any corrections/value additions - Changeover time should ideally be less than 10 minutes (Singe fraction minute exchange of dies) 8. Standardize the process for further improvement & horizontal deployment on similar process across the organization 9. Appreciate the team with rewards & recognition for further promotion of SMED initiatives across organization Suitable examples are working with a pit crew in racing team, Quick changeover for machine stoppage in production line, SMED oriented stamping process changeovers etc