Set-up Time Reduction / SMED (Single Minute Exchange of Die)

Based on a systematic approach and the use of well-known CIP/LEAN tools the set-up time reduction, also known as SMED, provides a drastic and sustainable reduction of set-up and machine down times. The thereby gained capacity allows the production in small batches and low work in progress and hence creates a lean production. Short set-up times are the prerequisite for flexibility on customer demands and allow an economic production with high diversity.

Content / Structure

  • Training of the participants including hands-on exercises and explanation of the analysis method; target group: employees of production and related areas (e.g. scheduling, quality)
  • Practice related training of all participants e.g. set-up game Formula 1
  • Demarcation of the area to be analyzed
  • Video- and/or data recording of the set-up processes to be analyzed
  • Identification and documentation of optimization including evaluation of the potential (workflow analysis)
  • Distinction between real set-up and not set-up related activities
  • Distinction between internal and external activities
  • Identification of the major time losses/waste (use of Pareto diagram)
  • Realization of short term optimization activities, scheduling of medium term activities
  • Determination of new standard, working instructions and rules
  • Implementation of the new set-up process
  • Approval and documentation of the new set-up time

What do you get on top of this?

  • EOPplus (Equipment Optimization process) – we go a step further and optimize clamping devices, tools and control programs
  • TPM as an additional method for the maintenance of the machine efficiency
  • V² Advanced Development & Sales supports the prompt implementation by purchase or quick development of individual production equipment (e.g. set-up carts)