A Revolution in Manufacturing: The SMED System by Shigeo Shingo, Andrew P. Dillon

By Shigeo Shingo, Andrew P. Dillon

Written by way of the economic engineer who built SMED (single-minute trade of die) for Toyota, A Revolution in production presents an entire review of this strong simply in time creation instrument. It deals the main entire and exact directions to be had at any place for reworking a producing setting in ways in which will accelerate construction and make small lot inventories possible. the writer delves into either the speculation and perform of the SMED procedure, explaining basics in addition to strategies for utilizing SMED. The significantly acclaimed textual content is supported with thousands of illustrations and pictures, in addition to twelve chapter-length case reports.

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36 100 4hrs. 10,000 1 min. 1 m i n . + ^ ^ = 1 . 0 2 4 min. 30 83 100 TABLE 2 - 1 . Relationship Between Setup T i m e and L o t Size—I As Table 2-1 shows, increasing the lot size from 100 to 1,000 units leads to a 64% reduction in production man-hours. When lot size is increased by another factor often, however, to 10,000 units, the related decrease in man-hours is only 17%. In other words, increasing the size of a small lot leads to a relatively large decrease in man-hours, but as size increases the rate of reduction in man-hours decreases.

In particular, inadequate repairs to presses and plastic molds are sometimes discovered only after test runs have been completed. In this event, molds that one has already taken the trouble to mount on a machine must be removed and repaired, thus increasing setup time substantially. One frequent problem is repairs that are anticipated, but take longer than expected. The operation is begun before repairs are completed. When defective goods show up as a result, the die is hurriedly removed, and further repairs are made, interrupting production.

Dies to be used in the following operation were preheated by heat dissipated from the holding oven. Using recycled heat to preheat the dies killed two birds with one stone. The only expense the company incurred was the cost of building a special rack strong enough to hold the dies (Plate 4-1). PLATE 4-1. Preheating of Dies Die Preheating on a Large Plastic-Molding Machine As in the previous example, dies had been preheated by injecting molten resin. Preheating the mold with an electric heater before attaching it to the machine made it possible to produce quality goods 38 T H E S M E D SYSTEM right from the beginning of each lot.

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