How can you use SMED to reduce changeover time in your injection molding machine?

1 What is SMED?

SMED stands for Single-Minute Exchange of Die, and it was developed by Shigeo Shingo, a Japanese industrial engineer and lean pioneer. SMED is based on the idea that any setup activity can be classified into two types: internal and external. Internal activities are those that can only be done when the machine is stopped, such as changing the mold, adjusting the parameters, or performing quality checks. External activities are those that can be done while the machine is running, such as preparing the materials, tools, or documents, or cleaning the work area. The goal of SMED is to convert as many internal activities as possible into external activities, so that the machine downtime is minimized.

2 How does SMED work?

SMED works by following a four-step process that involves observing, analyzing, improving, and standardizing the setup activities. To begin, you should observe the current setup process and record the time and sequence of each activity using a stopwatch, a video camera, or a checklist. Then, analyze the data to look for opportunities to reduce or combine activities. After that, implement the improvements and measure the new setup time. Finally, standardize the new setup process and document it in detail. This should include creating a procedure that specifies roles, responsibilities, tools, and steps for each activity. Additionally, train operators and provide them with visual aids such as checklists or diagrams.

3 How can you use SMED in your injection molding machine?

To use SMED in your injection molding machine, you need to follow the four-step process and apply it to your specific situation. Here are some general tips and examples that can help you get started: eliminate unnecessary activities, simplify complex or difficult activities, combine multiple activities, convert internal activities into external activities, organize the work area and tools, and optimize the quality and performance. For instance, you can use standardized molds and materials or combine changing molds and materials at the same time. Additionally, you can use quick-change systems such as magnetic clamps or modular molds, and employ poke-yoke or mistake-proofing devices to prevent defects or rework.

4 What are the benefits of SMED in your injection molding machine?

By using SMED in your injection molding machine, you can enjoy several benefits that can boost your competitiveness and customer satisfaction. Reduced setup time will allow for more production time, higher output, and lower costs. Additionally, reduced inventory and waste leads to less space, capital, and energy required as well as less environmental impact. Furthermore, increased flexibility and responsiveness provides more ability to meet customer demand, offer variety, and customize products. Finally, improved quality and reliability leads to less defects, rework, and downtime - resulting in greater customer satisfaction and loyalty.

5 How can you sustain SMED in your injection molding machine?

To sustain SMED in your injection molding machine, it is essential to make it a part of your continuous improvement culture and practice. You should monitor and measure the setup time and quality and performance indicators regularly to identify gaps and improvement opportunities. Additionally, involve and empower the operators and team members in the SMED process, provide training and coaching on the principles and techniques, and recognize and reward their efforts for reducing setup time and improving quality and performance. All of these steps will help create a culture of continuous improvement.

6 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?