Smed method

The SMED method, or the quick change method, helps us reduce the time it takes to change a tool or product in the work process. Due to the growing number of product versions and the size of the batches we produce, the SMED method can achieve very large savings in the availability of our working resources.

Changes in the economic environment require companies to respond flexibly to the changing demands of their customers. Therefore, a rapid change process is needed. If a company has a large product portfolio, there are basically only two options; integrate production into large batches or change the production program frequently. Frequent changes associated with the machine replacement process are optimized using the SMED method. The main goal is to use SMED (Single Minute Exchange of Die) on lines or machines where we make a lot of items. The results of various academic studies on cases from all industries show that it is possible to save up to 40% of the time companies currently spend on exchanges.

When using SMED, the improvements are noticeable in a very fast time, the results we have achieved with our customers show a reduction in the time of changes from 25% to as much as 85%. Shorter replacement times increase production flexibility, as we can afford more frequent product changes. In addition, machine utilization and equipment capacity increase with shorter downtime during shifts.

SMED method – fast exchanges help us reduce one of the biggest activities without added value – exchanges

The SMED method is a tool-method for reducing losses in the production process with an emphasis on the time of tool changes on machines. It allows us to efficiently change tools, which is the first condition for smaller production batches. During tool change and adjustment, the machine does not operate and thus does not create any added value, so the change must be carried out as quickly and efficiently as possible. Today, customers demand more and more small batches from us and are willing to pay only added value, which requires regular tool changes. This increases the downtime of the machine, which means direct loss and lower OEE of the machines.

In short, we can summarize that tool changes are necessary to change products, but this does not bring added value for the customer, so this can be classified as a loss. By shortening the exchange times, they therefore directly reduce the loss (in time). This can be done by eliminating redundant activities or by their different sequence, preparation for exchange, etc.

• Allows more frequent tool changes
• It allows the production of small batches of products
• Reduces inventories (input, interphase and output)
• Gaining space (less stock)
• Reduces production costs
• Better responsiveness to customer requirements (better customization in planning) – shorter delivery times
• Increase productivity
• Improved production flow
• Less excrement
• Increased competitive advantage of the company

SMED is a method of dramatically reducing the time required to complete a complete replacement of equipment or tools on a machine. The phrase ‘single minute’ is an expression for a target shift time that can be written in one digit (< 10 min).

• Internal operations: can only be performed when the machine is stopped.

• External operations: can also be performed when the machine is running at full speed

Focusing on the physical change of tools, while forgetting the time to stop the machine before changing and the time to restart the machine.

A real example of savings in reducing the shift times of one of our customers:

The SMED method is not just one of the exercises to reduce costs, but it is a method to reduce inventory, a method to flexibly set up a more efficient, safer and easier process.

It’s a team activity! All actors (participants) who make exchanges and are in any way related to the process must be involved.

A short instructive video on the topic of brown methods

The support and motivation of the company’s management is crucial at this starting point. Lean or lean production, efficiency, productivity, reliability, availability, performance, management, process optimization, with methods: TPM , 5S , Kaizen , SMED , SFM , etc., are indispensable elements of any organization that wants to successfully compete in the global market.

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With the help of Lean methods, we eliminate losses and activities without added value in a structured way. Teamwork and cooperation between different departments is important, and for the progress of the company we provide an excellent user experience and a return on investment.