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QUICK CHANGEOVER FOR OPERATORS
The SMED System
Productivity Press Development Team


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The heart of just-in-time (JIT) manufacturing is quick changeover methods. Application of Shingo's techniques can reduce lead time from weeks to days, lower work-in-process inventory, and reduce warehousing costs. Quality, productivity, and profits will all be on the increase. The powerful knowledge contained in this book can make your workplace more productive, your job simpler, and everything more satisfying. It's about how to do equipment or product changeovers in record time--often in under 10 minutes. The method you'll learn here is called SMED, short for "Single-Minute Exchange of Die" (the "single" here means a single-digit number of minutes--less than 10).

So What's SMED?In one of the first applications of SMED, Toyota was able to shorten setup on a thousand-ton stamping press from 4 hours to a mere 3 minutes. Quick changeovers are critical for any company wanting to practice just-in-time or one-piece flow manufacturing, since models may be rapidly switched and unneeded inventory may be avoided. SMED reduces difficult, time-consuming, and wasteful activities in your company, which ultimately supports your company's competitiveness and makes your own work much easier. The SMED system you'll learn in this book is the most effective approach for shortening changeover time.

SMED is really about observing, thinking, and acting on changeover. You observe how things are done presently, you think about and note how the situation can be improved, and then you try to work on how the necessary setup work can be done in the shortest possible downtime.

Quick Changeover for Operators was developed from a longer book, A Revolution in Manufacturing: The SMED System, written for managers. But when you get right down to it, you--the frontline production and assembly associates--are the ones who'll be most involved in implementing the SMED approach--and also the ones who'll most benefit from it. We've developed this book specifically to give you the SMED basics in a straightforward and interesting format. Once you understand these basics, you'll be able to see how they might apply to your specific situation at work.

This book presents an overview of the reasons why SMED is important for companies and employees, sets out the three basic stages of SMED, and then devotes a separate chapter to each of these stages. The first chapter of the book is like an "owner's manual" that tells you how to get the most out of your reading time by using the margin assists, summaries, and other features of the book to help you pull out exactly what you need.

One of the most effective ways to use this book is to read and discuss it with other employees in group learning sessions. We've deliberately planned the book so that it can be used this way--by organizing the book into chunks of information that can be covered in a series of short session or in one longer event. (Most chapters can be covered in a single session; Chapter 5 and 6 contain a lot of samples, and each should probably be covered in two sessions.) Each chapter includes reflection questions to stimulate group discussion. A Learning Package is also available, which includes a leader's guide, overhead transparencies to summarize major points, and color slides showing examples of SMED applications in different kinds of companies.

80 pages, cartoons, illustrations, charts, 1996

ISBN No/Item Code: 9781563271250


   
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