SMED

SMED
Dicetuskan oleh Shigeo Shingo
Tahun 1950 di Jepang
Shigeo Shingo (新郷重夫, Shingō
Shigeo, 1909 - 1990), Born in Saga
(Single Minutes Exchange of Dies) City, Japan,
He was a Japanese industrial engineer
who distinguished himself as one of
the world’s leading experts on
Winda Halim, ST., MT manufacturing practices and the
IE-402 Analisis Perancangan Kerja dan Ergonomi 2 Toyota Production System.
Jurusan Teknik Industri
Fakutas Teknik
Universitas Kristen Maranatha

SMED is Continuous Improvement Latar Belakang Masalah

Berdasarkan kebutuhan konsumen, karena konsumen
selalu meminta lebih (demanding customer) : • Persentase waktu setup yang tinggi dalam
Keragaman produk dan jasa melakukan suatu pekerjaan.
Harga yang murah • Pemakaian waktu kerja yang kurang
Kualitas dan reliabilitas yang tinggi efisien.
Sehingga organisasi harus menjadi semakin ramping
(leaner), dengan cara :
Produce smaller lots, more frequently.
Expand the scope and diversity of products and
services. CHANGEOVER or SETUP
Reduce quality defects.

Traditional Setup Practices

Terjadi pergerakan
material setelah mesin
• Produk yang telah selesai dipindahkan
dimatikan ke proses selanjutnya
• Bahan mentah dipindahkan setelah
mesin berhenti
Cacat atau peralatan yang
hilang terdeteksi saat mesin • Peralatan setup dikirim setelah
sedang berjalan changeover/ perpindahan terjadi
• Produk defektif teridentifikasi setelah
internal setup dimulai

Peralatan, cetakan, dan

instrumen setup yang defektif
diketahui setelah mesin • Operator menyadari terjadi kesalahan
dinyalakan setelah internal setup dimulai

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 Think Break Examples of wastes in a traditional setup !
5 “Traditional”Setup Steps Defined
What kind of “setup wastes” can you identify in this pictures ?
• Preparation - Ensures that all the tools are working properly and
are in the right location.
• Mounting & Extraction - Involves the removal of the tooling after
the production lot is completed and the placement of the new
tooling before the next production lot.
• Establishing Control Settings - Setting all the process control
settings prior to the production run. Inclusive of calibrations and
measurements needed to make the machine, tooling operate
effectively.
• First Run Capability - This includes the necessary adjustments(
re-calibrations, additional measurements) required after the first
trial pieces are produced.
• Setup Improvement- The time after processing during which the
tooling, machinery is cleaned, identified, and tested for
functionality prior to storage.
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SMED terfokus pada pengurangan changeover and set-up Manfaat Mengurangi Proses Set-
times, sehingga pabrik tersebut dapat: up/changeover
Increased customer service levels
and profits !
Via Waste Elimination resulting in:
Produce smaller lots of products and services more Reduced Lead Times-Faster Delivery
frequently !
Zero Inventories-Reduced Working Capital
Develop a broader scope of products and services ! Improved Quality
Reduce quality defects towards zero ! Improved Safety
Smaller lots of products-flexibility
Diversified Product & Service Options
Meet Customer’s Expectations !
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Manfaat SMED Manfaat SMED (cont’d)

 Untuk menghilangkan limbah yang dihasilkan
dari proses yang “tidak terkendali" sehingga dapat • Reduced setup time • Increased flexibility
mengakibatkan peningkatan persediaan dan lead • Higher efficiencies • Elimination of waiting
time. • Increased capacity • Operators preference
 Untuk mendapatkan kontrol pada peralatan, • Reduced WIP’s • Stockless production
bahan & persediaan. • Lower batch sizes
 Menerapkan teknik pengendalian untuk • Increased safety
mencegah terkikisnya perbaikan.
Standarisasi perbaikan untuk pemeliharaan
set-up parameter kritis/ penting.

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 SMED Internal Vs. External Setup
Suatu konsep atau prosedur untuk : • SETUP = Suatu aktivitas yang dilakukan sebelum
melaksanakan pekerjaan, yang bertujuan untuk
Meminimasi waktu penyelesaian suatu mempersiapkan bahan dan/atau alat/mesin.
pekerjaan.
Terbagi menjadi :
Meminimasi waktu menganggur.
• External Setup: Setup yang dapat dilakukan
Syarat : walaupun mesin sedang beroperasi
Pada saat melakukan aktivitas, mesin • Internal Setup: Setup yang dapat dilakukan
bekerja mandiri saat mesin dalam keadaan mati

One Step Setup Combining equipment functionality

Implementation
Plan

Involves standardizing the equipment ( parts, tooling, processes) based

Step 1 Step 2 Step 3 Step 4 Step 5 on commonality between setups to reduce the number of setup steps
Develop One Step Setup Develop Specific Develop Communication Develop One Step Implement One Step
Implementation Team Implementation Plan Plan Setup Training Plan Set-up
and cycle times.
The common setup parts were identified and
By using these replaced with this jig/holder combination.
fixtures, the
parts are
Notice how
Separate Internal automatically
Progressive different
from External Reduction of Setup centered and
Processes quantities of the
Setup Enhancements adjusted for
same part can
height and
be setup with
flatness as a
the same
Optimizing Setup part of External
Integrate Internal into
Processes fixture. Also,
External Setup setup-not
these setups
Internal setup.
Step 6 can occur while
Verification / Standardization the machine is
running.
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SMED Examples

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 Waste associated with finding, replacing, motion will be
eliminated by this example of visual placement.

Tooling supplies are clearly Tooling supplies are neatly assigned

labeled a unique location.

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Major
Tool Kit Comparison
CPI
Tools (6s) Kaizen Lean Description

Cp/Cpk 4 Process capability assessment

DOE 4 Design of experiments
SPC 4 Process control based on statistics and data analysis
FMEA 4 Risk assessment tool
Regression 4 Correlate effect one variable has on another
Process Map 4 4 4 Map process steps to communicate and identify opportunities
5 whys /2 hows 4 4 4 Determination methods for root cause discovery
Pareto 4 4 4 Column chart ranking items highest to lowest
Fishbone 4 4 4 Cause / Effect Diagram
5S 4 4 Elimination waste
Visual Mgmt 4 4 4 Emphasis on visual techniques to manage process
Poka-Yoke 4 4 Error proofing techniques
Kanban 4 4 Material storage technique used to control process
Takt Time 4 4 Determine pace or beat of a process
Std Work 4 4 Evaluate tasks done during a process
SMED 4 4 Single minute exchange of dies - Quick machine set up
TPM 4 Integrate maintenance strategy with process
Cellular Flow 4 Reduce inventory & cycle time through process layout and pull
production techniques

Expand Process Improvement Program to Utilize Kaizen Tool Kit 21