1 ASTRATEGY FOR PERFORMANCE EXCELLENCE SMED ( One Step Setup) Set-up and changeover reductions for equipment, tooling and machines.Executive Overview Participant manual Tools Workbook Knowledge Breakthrough Lecture notes Lecture notes Performance Excellence Series Training Module Elements Session 1.0 Introduction…….……...…... 4 Session 2.0 Waste Management . 12 Session 3.0 Setup Practices……..22 Session 4.0 Traditional /Strategic Setup Approach…… 29 Session 5.0 SMED Implementation Planning….34 Element 5.1 Implementation Team 36 Element 5.2 Implementation Plan.37 Element 5.3 Communication Plan.38 Element 5.4 Training Plan.40 Element 5.5 One Step Setup…….. 42 Element 5.5.1 Separate Internal from External Setup…… 44 Element 5.5.2 Integrating Internal into External Setup….49 Element 5.5.3 Reducing Setup Processing Time….63 Element 5.5.4 Optimizing Setup Processes..92 Element 5.6 Verification & Standardization……95 Session 6.0 Summary……105 Table of Contents Knowledge Breakthrough SMEDSMED is Continuous Improvement It is a customer driven requirement. Customers are demanding: Product and service diversity Lower costs Higher reliability and quality. In essence organizations need to become leaner ! So organizations must: Produce smaller lots, more frequently. Expand the scope and diversity of products and services. Reduce quality defects.Ultimately, SMED focuses on reducing changeover and set-up times, thus enabling organizations to: Produce smaller lots of products and services more frequently ! Develop a broader scope of products and services ! Reduce quality defects towards zero ! Meet Customer’s Expectations !What Does Set-up/changeover reduction mean for my business Increased customer service levels and profits! Via Waste Elimination resulting in: Reduced Lead Times-Faster Delivery Zero Inventories-Reduced Working Capital Improved Quality Improved Safety Smaller lots of products-flexibility Diversified Product & Service Options