Under this we have proposed a Lean Manufacturing technique which is named as SMED to reduce the Setup time and Changeover time of the manufacturing process in a heavy machine shop.

1. Implementation of SMED (Single Minute Exchange
of Dies) in Heavy Machine Shop
Register Number Students Name
511316114053 NAVEEN K
511316114058 PAVITHRA M M
511316114066 RUDHRA RAJ V
511316114073 SIDDHARTH M
Under the Guidance of
Mr. S. Mahendiran, M.E.,
Head of the department,
Department of Mechanical Engineering,
Kingston Engineering College.

2.  Abstract
 Introduction
 Problem Identification
 Literature Review
 Objective
 Methodology
 Working
 Design overview
 Prototype
 Benefits
 Conclusion
 References

3. Single Minute Exchange of Dies is a process of minimizing
the changeover time (or setup time) from hours to minutes (i.e.
less than 10 minutes). SMED is one of the lean production
methods, having several steps for implementation, is also used to
focus for reducing waste in a manufacturing process and to
increase the overall equipment effectiveness (OEE) in the shop
floor.
In this project, the availability is found and analyzed, the
time study plan of changeover time was taken, pallet design was
created, and applied all the steps of SMED. As a result, the
production rate can be achieved more and non-value added
activities can be eliminated as much as possible.

4. • Setup time: The time taken to
prepare the manufacturing processes
and system for production.
• Changeover time: The time taken
to modify the production line for
different products or new batches of
the same product.
• SMED helps reduce time in both
setup and changeover.
• Both setup and changeover are Non-
Value Added (NVA) operations and
so should be minimized as much as
possible.

5. • CNC boring machines does not have in-built pallets.
• Batch production & its size is min 1 to max 3.

6. • Machine schedules are dynamic in nature due to
varying customer demands.
• Parts varieties are more. Each parts having 23
variants.

7. • Parts are heavy weight in nature with weight 2 tons to
25 tons with more time for positioning (10-30min).

8. Title Author /
Publication
Key findings
Reduction in Setup Time
by SMED
Methodology
Prof. Nagaraj A Raikar
Assistant Professor Dept
of Mechanical
Engineering AITD,
Assagao GOA
International Journal of
Latest Trends in
Engineering and
Technology (IJLTET)
This Study is carried
out in one of the
automotive industry. This
document demonstrates
the need to overcome
most of bottleneck of
equipment’s
unavailability for
resources utilization.
Single Minute Exchange
of Die. A Case Study
Implementation
António Carrizo Moreira 1
, Gil Campos Silva Pais 2.
Journal of Technology
Management &
Innovation
Main finding is that by
implementing SMED
techniques the firm
managed to
eliminate wastefulness
and non-added value
activities

9. Title Author /
Publication / Year
Key findings
An Industrial Application
Of The Smed
Methodology
And Other Lean
Production Tools
Eric Costa1, Rui Sousa,
Sara Bragança, Anabela
Alves
Centre for Industrial and
Technology Management,
Department of
Production and Systems
(DPS), University of
Minho, Guimarães,
Portugal
This paper describes the
improvement of the
setup process of a
mechanical press
machine in
the metal-mechanic area
of a company.
The Implementation of
Single Minute Exchange
of Die with 5’S in
Machining Processes for
reduction of Setup Time
Vipan Kumar, Amit Bajaj
International Journal on
Recent Technologies in
Mechanical and Electrical
Engineering (IJRMEE)
In this paper we describe
that how the SMED
technique is used and
how it helps to reduce
the time and increasing
the productivity

10. The main objective of a project:
• To Improve OEE to Global benchmark 85%.
• Overall Equipment Effectiveness = Availability X
Performance X Quality

11. AVAILABILITY PERFORMANCE QUALITY
74% 92% 99%
OEE
68%
Lowest of OEE Parameter is Availability
What is Availability?
Availability = Machine cutting time / Machine available time
How to improve Availability?
Availability can be improved by reducing the non cutting time

12. Non cutting time
This 3 Non cutting
times are 70 %
Affect to OEE.
Cutting Time

13. Unloading fixture
Time = 16 min 38 sec
Machine table cleaning
Time = 19 min 42 sec
Fixture loading & clamping
Time = 15 min 53 sec
Job loading & aligning
Time = 12 min 43 sec
Job aligning
Time = 16 min 33 sec
Job clamping
Time = 9 min 7 sec
Origin loading
Time = 17 min 46 sec
Set up (Change over) time:
Elapsed time from completion of Part 1 to Start machining of Part 2
= 108 min 22 sec +
crane waiting time
approx. 60 min.
Totally 2 hrs 48
min in old
method.

14. Time study of Change over time
Average Change over time matrix
Four side machining parts Single side machining parts
Press Sizes Base Top – Links Side plate Side Link
65” TCP 180 min 22 sec 180 min 34 sec 120 min 28 sec 90 min 36 sec
91” TCP 220 min 46 sec 180 min 24 sec 180 min 42 sec 120 min 21 sec
104” TCP 240 min 15 sec 180 min 41 sec 180 min 33 sec 150 min 49 sec
To Reduce The Setup Losses , Change Over Time Needs To Be Reduced

15. Traditional effort taken to reduce Setup time:
• Additional manpower introduced for Set up in
machine.
• Modular fixtures and hydraulic clamping
systems.
Solution:
SMED (Single Minute Exchange of Dies) approach
for reducing setup time.

16. SMED (Changeover Reduction) is a tool supporting
Lean Manufacturing. It is used to control and decrease
downtime due to changeovers.

17. Took time
study plan of
change over
time
Analyze each
step of the
change over
process
Separate
internal &
external
activities
Convert
external to
internal
activities
Streamline
internal &
external
activities
Continuous
improvement
Steps in implementing SMED

18. TIME PROCESS TIME
TAKEN
(IN MINS)
2:15 pm Previous job completed
(1st shift over)
2:30 pm Labour called for
unclamping and
cleaning
15:22
2:31 pm Unclamping started 3:52
2:33 pm Crane arrived 2:15
2:34 pm Burr cleaning started 1:24
2:35 pm Belt fitted (to lift the
job)
1:14
2:37 pm Crane movement
started
3:18
2:40 pm Burr cleaning finished 9:75
2:50 pm Idle time 17:30
3:08 pm Crane departure 2:57
3:11 pm Side angle plate fixing 3:02
3.15 pm De clamping 1:40
3:16 pm Crane arrival 3:59
3:20 pm Stud removal 6:30
3:26 pm Full cleaning of job
including floor
8:47
3:35 pm Jig setting 6:46
3:42 pm Clamping new job 9:07
3:51 pm Jig origin (adjustment) 3:36
3:54 pm Tool setting 2:53
3:56 pm Machine idle 1:05
3:57 pm Tool origin 7:40
4:05 pm Workpiece origin 6.30
TIME PROCESS TIME
TAKEN
(IN MINS)

19. Existing Job &
Fixture
unloading
Machine
Cleaning
Top Link
Fixture
Loading
Fixture
Clamping
Job Tilting
And Loading
Crane
Waiting
Job Aligning
Job
Clamping
Origin
loading
Part 1
completed
Part 2
started
Internal External

20. TIME PROCESS TIME
TAKEN
(IN MINS)
2:15 pm Previous job completed
(1st shift over)
2:30 pm Labour called for
unclamping and
cleaning
15:22
2:31 pm Unclamping started 3:52
2:33 pm Crane arrived 2:15
2:34 pm Burr cleaning started 1:24
2:35 pm Belt fitted (to lift the
job)
1:14
2:37 pm Crane movement
started
3:18
2.40 pm Burr cleaning finished 9:75
2:50 pm Idle time 17:30
3:08 pm Crane departure 2:57
3:11 pm Side angle plate
removing
3:02
3.15 pm De clamping 1:40
3:16 pm Crane arrival 3:59
3:20 pm Stud removal 6:30
3:26 pm Full cleaning of job
including floor
8:47
3:35 pm Jig setting 6:46
3:42 pm Clamping new job 9:07
3:51 pm Jig origin (adjustment) 3:36
3:54 pm Tool setting 2:53
3:56 pm Machine idle 1:05
3:57 pm Tool origin 7:40
4:05 pm Workpiece origin 6:30
TIME PROCESS TIME
TAKEN
(IN MINS)

22. TIME PROCESS TIME
TAKEN
(IN MINS)
2:15 pm Previous job completed
(1st shift over)
2:30 pm Labour called for
unclamping and
cleaning
15:22
2:31 pm Unclamping started 3:52
2:33 pm Crane arrived 2:15
2:34 pm Burr cleaning started 1:24
2:35 pm Belt fitted (to lift the
job)
1:14
2:37 pm Crane movement
started
3:18
2.40 pm Burr cleaning finished 9:75
2:50 pm Idle time 17:30
3:08 pm Crane departure 2:57
3:11 pm Side angle plate
removing
3:02
3.15 pm De clamping 1:40
3:16 pm Crane arrival 3:59
3:20 pm Stud removal 6:30
3:26 pm Full cleaning of job
including floor
8:47
3:35 pm Jig setting 6:46
3:42 pm Clamping new job 9:07
3:51 pm Jig origin (adjustment) 3:36
3:54 pm Tool setting 2:53
3:56 pm Machine idle 1:05
3:57 pm Tool origin 7:40
4:05 pm Workpiece origin 6:30
TIME PROCESS TIME
TAKEN
(IN MINS)

23. • We designed a Pallet to reduce the setup time
of the machinery and improve the productivity.
• With the help of this Pallet, we can externally
clamp the fixtures and workpiece in it.
• Because of this Pallet, the internal works are
partially converted into external works.
• Now we can easily load the entire arrangement
in the worktable with the help of crane.

24. Before SMED

25. SMED design with pallet

26. Before SMED – without
pallet
After SMED – with
pallet

27. • Productivity increases or reduced production
time.
• Improved Machine Utilization.
• Economically beneficial to the organization.
• Improved Responsiveness to the Customer
Demand.
• Reduction in WIP and lot size reduction.

28. The development of this project enabled a
thorough setup diagnosis, which underpinned the
identification of critical points and their solutions.
In this project the importance of setup time
reduction was presented using SMED methodologies.
After implementing the SMED methodology, it is possible
to defend that simple process based innovations, the
separation of internal from external operations and the
conversion of internal to external operations, are the key
drivers to productivity improvement.

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•DAMANPOUR, F. (1991). Organizational innovation: A meta-
analysis of effects of determinants and moderators. Academy of
Management Journal, 34 (3), 555-590.
•DYER, J.H. (1996). Specialized supplier networks as a source of
competitive advantage: evidence from the auto industry. Strategic
Management Journal, 15, 271-291.