Smed Training Model Trainer Instructions[1]

PRESENTATION OF MODEL IN INITIAL CONFIGURATION SHOWING TOOL PART # 1

PRESENTATION OF MODEL IN INITIAL CONFIGURATION SHOWING TOOL PART # 1 CLAMP ARM TOOL PART # 1 TOOL TIGHTENING BOLT TIGHTENING BOLT JAMB NUT CLAMP ARM JAMB NUT (UPPER) CLAMP ARM JAMB NUT (LOWER) FLAT PLAIN WASHER FLAT PLAIN WASHER FLAT PLAIN WASHER FLAT PLAIN WASHER THREADED ROD THREADED ROD NUT MACHINE PLATEN SHIM STOCK

PRESENTATION OF MODEL IN INITIAL CONFIGURATION SHOWING MATERIAL STORES FOR TOOL PART # 1 CLAMP ARM TOOL PART # 1 MACHINE PLATEN MATERIALS STORES SUPPORT POST SMALL WASHERS (MATERIAL STORES FOR TOOL PART # 1)

PRESENTATION OF MODEL IN INITIAL CONFIGURATION SHOWING TOOL PART # 1 THREADED ROD SMALL WASHERS (MATERIAL STORES FOR TOOL PART # 1) TOOL PART # 1 MATERIAL STORES SUPPORT POST

TOOL PART #1 ALIGNMENT SETUP DIMENSIONS 1.6000” 0.3120” TOOL PART # 1

1.0000” 2.0225” 2.0225” TOOL PART #1 ALIGNMENT SETUP DIMENSIONS TOOL PART # 1

PRESENTATION OF MODEL IN INITIAL CONFIGURATION SHOWING TOOL PART # 2 CLAMP ARM TOOL PART # 2 TOOL TIGHTENING BOLT TIGHTENING BOLT JAMB NUT CLAMP ARM JAMB NUT (UPPER) CLAMP ARM JAMB NUT (LOWER) FLAT PLAIN WASHER FLAT PLAIN WASHER FLAT PLAIN WASHER FLAT PLAIN WASHER THREADED ROD THREADED ROD NUT MACHINE PLATEN SHIM STOCK

PRESENTATION OF MODEL IN INITIAL CONFIGURATION SHOWING MATERIAL STORES FOR TOOL PART # 2 CLAMP ARM MACHINE PLATEN MATERIALS STORES SUPPORT POST LARGE WASHERS (MATERIAL STORES FOR TOOL PART # 2) TOOL PART # 2 5/16”-18 X ½” SET SCREW

PRESENTATION OF MODEL IN INITIAL CONFIGURATION SHOWING TOOL PART # 2 THREADED ROD MATERIAL STORES SUPPORT POST LARGE WASHERS (MATERIAL STORES FOR TOOL PART # 2) TOOL PART # 2

TOOL PART #2 ALIGNMENT SETUP DIMENSIONS 1.6000” 0.3120” CLAMP ARM TOOL PART # 2

0.5000” 1.5225” 1.5225” TOOL PART #2 ALIGNMENT SETUP DIMENSIONS TOOL PART # 2

PRESENTATION OF MODEL IN FINAL CONFIGURATION SHOWING ALL FINAL IMPROVEMENTS CLAMP ARM TOOL TIGHTENING WING SCREW TIGHTENING BOLT JAMB WING NUT CLAMP ARM JAMB WING NUT (UPPER) CLAMP ARM JAMB WING NUT (LOWER) FLAT PLAIN WASHER FLAT PLAIN WASHER FLAT PLAIN WASHER FLAT PLAIN WASHER THREADED ROD THREADED ROD NUT MACHINE PLATEN TOOL STANDOFF ADAPTOR TOOL STANDOFF ADAPTOR CENTERING DOWEL PIN TOOL STANDOFF ADAPTOR LOCATION DOWEL PINS TOOL PART # 1

PRESENTATION OF MODEL IN FINAL CONFIGURATION SHOWING MATERIAL STORES IMPROVEMENT CLAMP ARM MACHINE PLATEN MATERIALS STORES SUPPORT POST WITH COLLAR SMALL WASHERS (MATERIAL STORES FOR TOOL PART # 1) TOOL PART # 1

PRESENTATION OF MODEL IN FINAL CONFIGURATION SHOWING ALL FINAL IMPROVEMENTS CLAMP ARM TOOL TIGHTENING WING SCREW TIGHTENING BOLT JAMB WING NUT CLAMP ARM JAMB WING NUT (UPPER) CLAMP ARM JAMB WING NUT (LOWER) FLAT PLAIN WASHER FLAT PLAIN WASHER FLAT PLAIN WASHER FLAT PLAIN WASHER THREADED ROD THREADED ROD NUT MACHINE PLATEN TOOL STANDOFF ADAPTOR TOOL STANDOFF ADAPTOR CENTERING DOWEL PIN TOOL STANDOFF ADAPTOR LOCATION DOWEL PINS TOOL PART # 2 5/16”-18 X ½” SET SCREW

PRESENTATION OF MODEL IN FINAL CONFIGURATION SHOWING MATERIAL STORES IMPROVEMENT CLAMP ARM MACHINE PLATEN MATERIALS STORES SUPPORT POST WITH COLLAR LARGE WASHERS (MATERIAL STORES FOR TOOL PART # 2) TOOL PART # 2

PRESENTATION OF MODEL IN FINAL CONFIGURATION SHOWING ALL FINAL IMPROVEMENTS SUPPORT POST LARGE WASHERS (MATERIAL STORES FOR TOOL PART # 2) SMALL WASHERS (MATERIAL STORES FOR TOOL PART # 1) TOOL STANDOFF ADAPTOR LOCATION DOWEL PIN TOOL STANDOFF ADAPTOR LOCATION DOWEL PIN TOOL PART # 1 TOOL PART # 2 TOOL STANDOFF ADAPTOR CENTERING DOWEL PIN

PRESENTATION OF MODEL IN FINAL CONFIGURATION SHOWING ALL FINAL IMPROVEMENTS

- INTRODUCTION - THE PURPOSE OF THIS TRAINING IS TO PROVIDE YOU WITH A SUPPORT FOR COORDINATING THE SMED TRAINING COURSE. IT WILL ENABLE ALL SMED PARTICIPANTS TO DISCOVER THE MOST IMPORTANT MESSAGES T BE CONVEYED DURING THE TRAINING COURSE AS WELL AS TO FACILITATE THEIR UNDERSTANDING OF THESE MESSAGES, WHICH IS PART OF THE GENERAL APPROACH TO IMPROVING PRODUCTION CHANGEOVER TIMES. THE TRAINING COURSE IS USED TO RAISE PARTICIPANT’S AWARENESS OF THE FOLLOWING IDEAS: REDUCING PRODUCTION CHANGEOVER TIMES IS NOT ONLY A TECHNICAL PROBLEM, BUT IS ALSO , TO A GREAT EXTENT AN ORGANIZATIONAL PROBLEM. A CERTAIN NUMBER OF OPERATIONS PERFORMED WHILE THE MACHINE IS STOPPED COULD BE PERFORMED DURING PREPARATION OR THE TIDYING UP PHASES. IT IS ALWAYS POSSIBLE TO REDUCE CHANGEOVER TIMES – ALWAYS… THIS TRAINING COURSE IS BASED ON A EXERCISE WHICH SIMULATES DIE CHANGEOVER ON A VERY SIMPLE MACHINE, ENABLING PARTICIPANTS TO LEARN THE SMED METHOD INTUITIVELY. IN FACT BY OPTIMIZING THE TOOL CHANGEOVER IN THE SIMPLE EXAMPLE USED PARTICIPANTS BECOME FAMILIAR WITH THE SMED METHOD WHICH IS PROPOSED TO THEM BY THE TRAINER WHILE THE EXERCISE TAKES PLACE. A FEW SLIDES SHOWN AT THE END OF EACH PHASE OF THE EXERCISE ARE USED TO CLARIFY THE VARIOUS STAGES OF THIS METHOD FOR OPTIMIZING DIE CHANGEOVER.

- SYMBOLS USED IN THIS TRAINER INSTRUCTIONS - USE THE FLIP CHART AS A COMMUNICATION TOOL. SLIDE NUMBER DISPLAY THE APPROPRIATE SLIDE ON PROJECTOR SCREEN. TIMED EXERCISE SEQUENCE. DISPLAY THE RECORDED ELEMENT OF THE TOOL CHANGEOVER. ADVISE COMMENTS & NOTES COMMENTS TO BE ADDED BY THE TRAINER. BLUE FONT COLOR: POINTS THE TRAINER SHOULD BEAR IN MIND DURING THE TRAINING COURSE .

- DESCRIPTION OF THE TRAINING KIT - THE TRAINING KIT CONTAINS THE FOLLOWING ITEMS: 1 MACHINE FITTED WITH INTERCHANGEABLE TOOLS COMPRISING 1 CLAMP ARM 1 5/16”-18 X 6” ALL THREAD ROD 4 5/16”-18 HEX NUTS 4 5/16” PLAIN FLAT WASHERS 1 5/16”-18 X 1 ½“ CLAMP ARM ALLEN CAP BOLT 1 5/16”-18 X ½“ SET SCREW 2 TOOLS (TOOL PART # 1 & TOOL PART # 2) 1 BOX OF SHIM STOCK (VARIOUS GAUGES FOR SETTING HEIGHT OF TOOL PART # 1 & TOOL PART # 2) 1 MATERIAL STORES PART # 1 SUPPORT POST 1 MATERIAL STORES PART # 2 SUPPORT POST 1 BOX OF ACCESSORIES COMPRISING 1 5/16”-18 X 1 ½“ WING SCREW 3 5/16”-18 WING NUTS 2 5/16” D X 1 ½” L TOOL STANDOFF ADAPTOR LOCATION DOWEL PINS 1 5/16” D X 1 ½” L TOLL STANDOFF ADAPTOR CENTERING DOWEL PIN 1 MATERIAL STORES PART # 1 SUPPORT POST (WITH COLLAR) 1 MATERIAL STORES PART # 2 SUPPORT POST (WITH COLLAR) 1 0.3120” DISTANCE GAUGE 1 TOOL STANDOFF ADAPTER (DIAMETER 3.0000” - HEIGHT 0.5500”) 1 TOOL STANDOFF ADAPTER 5/16” D X 1” L DOWEL PIN 1 BOX OF SMALL WASHERS CHANGEOVER MATERIALS STORES FOR TOOL PART # 1 1 BOX OF LARGE WASHERS CHANGEOVER MATERIALS STORES FOR TOOL PART # 2 1 BOX OF HAND TOOLS COMPRISING 1 SET OF OPEN & CLOSED END STANDARD WRENCHES (3/8” to 9/16”) 1 SET OF STANDARD ALLEN WRENCHES (1/16” to 3/8”) 1 MEASURING CALIPERS

- PRESENTATION OF THE MODEL IN INITIAL CONFIGURATION -

- SUMMARY: TRAINING COURSE IMPLEMENTATION - THE RAPID CHANGEOVER EXERCISE IS USED TO ILLUSTRATE THE SMED METHOD. THE GOAL THEREFORE IS TO ALLOW PARTICIPANTS TO DISCOVER CHRONOLOGICALLY THE VARIOUS IMPROVEMENT PHASES INCLUDED IN THIS METHOD. EXERCISE PHASES ALTERNATE WITH DEBRIEFING PHASES DURING WHICH THE TRAINER MY USE SLIDES TO PRESENT THE IMPORTANT ASPECTS OF THE APPROACH MORE ACCURATELY. AFTER INTRODUCING THE SMED, THE TRAINER PRESENTS THE EXERCISE & ALLOCATES ROLES TO PARTICIPANTS CLEARING SPECIFYING THE GOALS. A NON-PREPARED TOOL CHANGEOVER CONCEALING A CERTAIN NUMBER FAILURES IS THEN TIMED. GENERALLY THE FIRST TIME MEASUREMENT IS AROUND 5 MINUTES. THE GROUP THINKS ABOUT WHAT HAS JUST TAKEN PLACE & CONTINUES BY INTERNAL & EXTERNAL CATEGORIZATION OF OPERATIONS & PREPARATION CHECKLIST – THIS IS THE FIRST IMPROVEMENT STEP OF THE SMED METHOD. WHEN THE CHANGEOVER IS TIMED A 2 ND TIME, IT BECOMES EVIDENT THAT ALMOST 50% OF THE TIME IS GAINED PURELY TO IMPROVED ORGANIZATION (5S & HAVING A PREPARATION CHECKLIST) THE NEXT PHASE CONSISTS OF STUDYING THE TOOL CHANGEOVER OPERATIONS & LOOKING FOR ANY POSSIBLE IMPROVEMENTS. NEXT, ALL IDEAS PUT FORWARD ARE DIVIDED INTO TWO CATEGORIES: IDEAS REQUIRING LITTLE OR NO INVESTMENT & IDEAS REQUIRING A LARGER INVESTMENT. TO BEGIN WITH ONLY LOW-COST MODIFICATIONS ARE SELECTED. THE ACCESSORIES CONTAINED IN THE TRAINING KIT MAKE IT POSSIBLE TO PRODUCE A NUMBER OF SUCH IMPROVEMENTS. A 3 RD TIMING CONVEYS THE FACT THAT WITHOUT MAJOR MODIFICATIONS IT IS POSSIBLE TO REDUCE THE TIME IN RELATION TO THE PREVIOUS TIMING BY ANOTHER 50%. DURING THE NEXT PHASE OF THE EXERCISE A FEW MORE EXPENSIVE MODIFICATIONS (STANDARDIZATION OF TOOLS, INVESTMENT IN THE MACHINE) ARE IMPLEMENTED & MAKE IT POSSIBLE TO REDUCE THE TOOL CHANGEOVER TIME BY APPROXIMATELY 10 SECONDS. AT THIS POINT THE TRAINER MUST INSIST ON SYNCHRONIZING ( SIMULTANEOUS ) TASKS, WHICH IS A CRUCIAL POINT IN THE RECOGNIZING OF A DIE CHANGEOVER (ONE WAY OF EMPHASIZING THIS POINT IS TO INTRODUCE IT AFTER THE 4 TH TIMING IT IS THEN OBSERVED THAT PURELY BY SYNCHRONIZING THE CHANGEOVER -

- SUMMARY: TRAINING COURSE IMPLEMENTATION CONT. - TIME CAN BE CUT BY HALF OR MORE ) THE CONCLUSION IS THAT DIE CHANGEOVER TIMES CAN BE VASTLY REDUCED FIRSTLY THROUGH IMPROVEMENT IN ORGANIZATION & SECONDLY BY MEANS OF MINOR MODIFICATIONS , CHANGES TO WHICH OPERATORS ARE MORE RESISTANT TO AS THEY ARE AFFECTED MORE DIRECTLY.

- TRAINING COURSE IMPLEMENTATION - TIME MEANS USED TRAINING SESSION IMPLEMENTATION ADVICE/COMMENTS/NOTES FOR TRAINER WHAT IS S.M.E.D? BY TRYING TO UNDERSTAND WHAT SMED MEANS THE GROUP WILL GRADUALLY DEFINE IT. THE FLIPCHART MAY BE USED TO RECORD GOOD SUGGESTIONS FROM THE GROUP. SLIDE 1. ACCURATE DEFINITION OF PRODUCTION CHANGEOVER TIME. REPRODUCE THE FOLLOWING DIAGRAM ON THE FLIPCHART: SINGLE MINUTE: A SINGLE DIGIT UNIT (LESS THAN 10 MINUTES) EXCHANGE: CHANGEOVER DIE: TOOL SINGLE MINUTE OF EXCHANGE OF DIE PRODUCTION CHANGEOVER OF LESS THAN 10 MINUTES PRODUCTION CHANGEOVER TIME = THE TIME BETWEEN THE LAST GOOD PART OF CURRENT PRODUCTION RUN & THE FIRST GOOD PART OF NEXT PRODUCTION RUN.

- TRAINING COURSE IMPLEMENTATION - TIME MEANS USED TRAINING SESSION IMPLEMENTATION ADVICE/COMMENTS/NOTES FOR TRAINER WHY MUST XYZ CORPORATION USE SMED TELL THE FOLLOWING STORY: IN THE 1920s AT THE FORD MOTOR COMPANY YOU COULD ORDER A MODEL T CAR IN ANY COLOR YOU WANT AS LONG AS IT IS BLACK. IN THE 1960s WHEN THE FRENCH MOTOR COMPANY CITROEN FIRST LAUNCHED THE 2CV CAR THERE WAS AS MUCH AS A ONE YEAR LEAD TIME (WAITING LIST) FOR BLUE. IN THE 1980s THE TOYOTA COROLLA CAR COMBINING A WHOLE RANGE OF INTERIOR/EXTERIOR COLORS, ENGINE, TRANSMISSION OPTIONS, MOTORIZATIONS VARIATIONS & THE CUSTOMER COULD EXPECT DELIVERY WITHIN 3 WEEKS OF PLACING AN ORDER. SLIDE 2. WHY USE SMED? SLIDE 3. WHAT DOES REDUCING MANUFACTURING LOT SIZE MEAN? TODAY THE CUSTOMER WANTS: SHORTER LEAD TIMES MORE DIVERSIFIED PRODUCTS BETTER QUALITY TO SATISFY THE CUSTOMER, IT IS NOW NECESSARY TO PRODUCE THE RIGHT PRODUCT AT THE RIGHT TIME . EITHER ONE CREATES ENORMOUS STOCKS WHICH WILL NEVER PERFECTLY MEET CUSTOMER REQUIREMENTS ANYWAY. OR ONE REDUCES THE MANUFACTURING LOT SIZE TO PRODUCE WHAT THE CUSTOMER WANTS (REDUCTION OF STOCKS). THIS IS ONLY POSSIBLE IF PRODUCTION CHANGEOVER TIMES ARE REDUCED. UNTIL TODAY, PRODUCTION WAS IN LARGE LOT TO COMPENSATE FOR RELATIVELY LONG PRODUCTION CHANGEOVER TIMES. IF THE PRODUCTION CHANGEOVER TIME IS REDUCED THEN IT IS POSSIBLE TO REDUCE THE SIZE OF LOTS. IF THE PRODUCT IS CHANGED TWICE AS OFTEN, IT IS POSSIBLE TO RESPOND TWICE AS QUICKLY TO CHANGES IN CUSTOMERS DEMANDS.

- TRAINING COURSE IMPLEMENTATION - TIME MEANS USED TRAINING SESSION IMPLEMENTATION ADVICE/COMMENTS/NOTES FOR TRAINER PRESENTATION OF THE RAPID TOOL CHANGEOVER KIT 1 – INTRODUCING THE KIT & SHOW IT TO PARTICIPANTS FOR THE TIME BEING, ONLY PRESENT: - THE SMALL TOOL (TOOL PART 1) MOUNTED ON THE MACHINE WITH THE MATERIAL STORES FILLED WITH THE SMALL DIAMETER WASHERS. THE EMPTY CONTAINER (FOR RAW MATERIALS) PLACED NEXT TO THE MACHINE. 2 – EXPLAINING THE SETUP CONDITIONS THIS INVOLVES CHANGING THE TOOL & THE RAW MATERIALS AS QUICKLY AS POSSIBLE. THE 3 POSITIONING ALIGNMENT DIMENSIONS (XYZ) OF THE TOOL IN RELATION TO THE MACHINE PLATEN MUST BE EQUAL (+/- 0.0395”) THE DISTANCE BETWEEN THE BOTTOM OF THE CLAMP ARM & THE TOP OF THE TOOL MUST BE SET TO 0.3120”(+/- 0.0395”) THE TOOL CHANGEOVER IS DEEMED ACCEPTABLE WHEN DIMENSIONAL CONDITIONS ARE COMPLIED WITH (OTHER WISE THE OPERATOR MUST RE-ADJUST THE TOOL UNTIL THESE DIMENSIONS ARE CORRECT. THE STOPWATCH CAN THEN BE STOPPED). THE PERSON SETTING UP THE TOOL ALWAYS USES APPROPRIATE DEVICES. THE PURPOSE OF THIS EXERCISE IS TO USE THE SMED METHOD TO SUCCEED IN IMPROVING THE CHANGEOVER OF A VERY SIMPLE TOOL IN THE SAME WAY THAT ONE MIGHT IMPROVE A DIE CHANGEOVER. THE APPROACH APPLIED HERE CAN BE APPLIED IN ITS ENTIRETY TO A 2000 TON PRESS.

- TRAINING COURSE IMPLEMENTATION - TIME MEANS USED TRAINING SESSION IMPLEMENTATION ADVICE/COMMENTS/NOTES FOR TRAINER 5m TO 6m PRESENTATION OF THE RAPID TOOL CHANGEOVER KIT 3 – ALLOCATE ROLES TO PARTICIPANTS 1 OPERATOR CHANGING THE TOOL. 1 SUPERVISOR (CHECKING THAT THE TOOL SET UP IS SET UP IN ACCORDANCE WITH THE REQUIRED DIMENSIONS). 1 TIMER (MEASURING THE TOOL CHANGEOVER TIME STOPPING THE STOPWATCH WHEN THE DIMENSIONS ARE SATISFACTORY). THE OTHER PARTICIPANTS ARE THERE TO RECORD EACH ACTION PERFORMED BY THE PERSON SETTING UP THE TOOL . THE OPERATOR IS PLACED OPPOSITE THE TRAINER WITH THE MODEL SET UP WITH THE TOOL PART # 1 & THE STORE OF THE SMALL DIAMETER WASHERS PLACED ON THE TABLE IN FRONT OF HIM/HER. 1 ST TIMING: NO PREPARATION WHEN THE OPERATOR ASKS FOR AN OPEN ENDED WRENCH, HAND HIM/HER ALL THE WRENCHES TIED TOGETHER WITH A RUBBER BAND. WHEN OPERATOR ASKS FOR THE 5/32” ALLEN WRENCH TO REMOVE THE SET SCREW ATTACHED TO TOOL PART # 2 THE TRAINER TAKES TIME IN EXPLAINING THAT IT IS BEING USED BY ANOTHER OPERATOR RIGHT NOW & HANDS OVER THE ALLEN WRENCH (SEARCHING WASTE). FOR THIS FIRST PHASE, THE TRAINER MUST HAVE THE FOLLOWING EQUIPMENT READY IN HIS KIT: 1 CONTAINER CONTAINING THE SMALL DIAMETER WASHERS 1 TOOLBOX CONTAINING: 1 SET OF STANDARD OPEN & CLOSED ENDED WRENCHES TIED UP WITH AN RUBBER BAND 1 SET OF ALLEN STANDARD WRENCHES 1 6” STEEL RULER 1 THE BLUE TOOL WITH AN UNUSED SET SCREW SCREWED INTO IT BASE. 1 NO. 3/16” ALLEN WRENCH (USED TO LOOSEN THE UNUSED SET SCREW IN THE BASE OF THE BLUE TOOL) WHICH HAS BEEN REMOVED FROM THE ALLEN WRENCH SET. THE MACHINE & TOOLS ADAPTATION ACCESSORIES. DURING THE 1 ST PHASE OF THE EXERCISE, THE TRAINER ACTS AS TOOL STORE MAN, TOOLING STORE MAN MATERIALS STORE MAN & WORKSHOP SUPERVISOR. HE ONLY HANDS OVER ITEMS FROM THE ABOVE LIST AT THE OPERATORS REQUEST. REMEMBER TO RECORD THE TIME MEASURED DURING THIS CHANGEOVER & SUBSEQUENT CHANGEOVERS. THIS WILL MAKE IT POSSIBLE TO COMPARE THE DIFFERENT TIMES AT THE END OF THE SESSION. CHECK THAT EACH PARTICIPANT IN THE EXERCISE UNDERSTANDS HIS/HER ROLE CORRECTLY.

- TRAINING COURSE IMPLEMENTATION - TIME MEANS USED TRAINING SESSION IMPLEMENTATION ADVICE/COMMENTS/NOTES FOR TRAINER ANALYSIS THE TOOL CHANGEOVER INVITE ONE OF THE PARTICIPANTS TO THE FLIP CHART & ASK THE GROUP TO ITEMIZE IN CHRONOLOGICAL ORDER EACH OPERATION (ELEMENT) PERFORMED BY THE PERSON SETTING UP THE TOOL. (A MODEL BREAKDOWN IS INCLUDED AT THE BEGINNING OF THIS PRESENTATION FOR REFERENCE PURPOSES). WHICH OPERATIONS IN THE EXERCISE CAN BE PERFORMED WHILE THE MACHINE IS RUNNING & WHICH MUST BE PERFORMED WHILE THE MACHINE IS STOPPED? WRITE (FOR EXAMPLE, ON THE FLIP CHART) A PREPARATION CHECKLIST & AN CHANGEOVER PROCEDURE FOR THE CHANGEOVER. IT IS IMPORTANT TO POINT OUT THAT EVERYBODY HAS PROBLEMS AGREEING ON THE CHANGEOVER PROCEDURE USED BY THE PERSON SETTING UP THE TOOL. A GOOD WAY OF ANALYZING THE DIE CHANGEOVER PROCEDURE PROPERLY IS THE TO USE THE RECORD VIDEO OF THE CHANGEOVER . DIVIDE THE OPERATIONS INTO CATEGORIES DIRECTLY ON THE FLIP CHART (FOR EXAMPLE, BY UNDERLINING EXTERNAL OPERATIONS). AS FAR AS POSSIBLE, ASK A PERSON FROM THE GROUP TO COME & WRITE ON THE FLIP CHART. A MODEL CHECKLIST & OPERATING PROCEDURE ARE INCLUDED IN THIS TRAINING KIT.

- TRAINING COURSE IMPLEMENTATION - TIME MEANS USED TRAINING SESSION IMPLEMENTATION ADVICE/COMMENTS/NOTES FOR TRAINER 1m 30s TO 2m SLIDE 4. PHASE 1 OF THE SMED METHOD: ORGANIZING THE TOOL CHANGEOVER 2 ND TIMING: PREPARED CHANGEOVER USE THE PREPARATION CHECKLIST TO CHECK THAT EVERYTHING IS PREPARED , MAKE THE OPERATOR REPEAT THE KEY POINTS OF THE CHANGEOVER PROCEDURE THEN CARRY OUT THE 2 ND TIMING. CONCLUSION: THANKS PURELY TO ORGANIZATION THE CHANGEOVER TIME IS CUT BY 2 OR 3. ORGANIZATION IS THEREFORE THE 1 ST IMPROVEMENT WHICH CAN INSTITUTED QUICKLY & WITH MINIMAL COST. THIS ORGANIZATION MUST BE TRIED OUT & PERFECTED CONTINUOUSLY. THIS ARRANGEMENT COMES BEFORE ANY TECHNICAL MODIFICATIONS. AT THE SAME TIME CREATE A MEANS OF MEASURING TO ASSESS THIS IMPROVED ORGANIZATION. EMPHASIZE THE DIFFERENCE BETWEEN INTERNAL & EXTERNAL OPERATIONS (ELEMENTS OF THE TOOL CHANGEOVER). THE BEST WAY OF NOT FORGETTING ANYTHING WHEN PREPARING A DIE CHANGEOVER IS TO WRITE A PREPARATION CHECKLIST. HOWEVER, TO BE EFFICIENT, A CHECKLIST & A CHANGEOVER PROCEDURE MUST TO USED. GET INTO THE HABIT OF OBSERVING A CHECKLIST OR AN CHANGEOVER PROCEDURE. TO MAKE PARTICIPANT FULLY AWARE OF THE IMPORTANCE OF A CLEARLY DEFINED (WRITTEN) CHECKLIST & CHANGEOVER PROCEDURE EXCHANGE PARTICIPANTS’ ROLES ESPECIALLY THAT OF THE OPERATOR CHANGING THE TOOL. THIS MAKES IT POSSIBLE TO PICK UP ON THE FACT THAT PRACTICE & THEREFORE KNOWLEDGE OF THE OPERATING PROCEDURE PLAYS AN IMPORTANT PART IN THE EFFICIENCY OF THE TEAM CHANGING THE TOOL. DO NOT FORGET TO TIME THIS EXERCISE SEQUENCE DEPENDING ON THE TRAINER, ONE MIGHT REACH THE CONCLUSION INTERACTIVELY BY THE GROUP WHAT CAN BE CONCLUDED FROM THIS 2 ND SEQUENCE AFTER ORGANIZING THE TOOL CHANGEOVER. USE FLIP CHART.

- TRAINING COURSE IMPLEMENTATION - TIME MEANS USED TRAINING SESSION IMPLEMENTATION ADVICE/COMMENTS/NOTES FOR TRAINER SLIDE 5. IMPROVING EACH ELEMENT HOW TO ELIMINATE OR IMPROVE EACH INTERNAL ELEMENT WITH THE GROUP EXAMINE EACH INTERNAL OPERATION (ELEMENT) CHRONOLOGICALLY IN ACCORDANCE WITH THE METHOD DESCRIBED PREVIOUSLY. DO NOT TRY TO FIND GLOBAL SOLUTIONS. ASK WHICH OF THE INTERNAL OPERATIONS (ELEMENTS) CAN BE PERFORMED EASILY, THAT IS WHICH ONES REQUIRE LITTLE OR NO INVESTMENT. IMPLEMENT THE MODIFICATIONS WHICH ARE POSSIBLE AT THIS LEVEL. AS THE GROUP TO REDEFINE (OR MODIFY) THE CHECKLIST & THE CHANGEOVER PROCEDURE ACCORDING TO THE NEW IMPROVEMENTS WHICH HAVE BEEN MADE. AFTER HAVING FOCUSED ON ORGANIZATION TECHNICAL IMPROVEMENTS MUST BE TACKLED. TO THIS END TRY TO ELIMINATE OR IMPROVE EACH OPERATION PERFORMED BY THE PERSON SETTING UP THE DIE. THE PURPOSE OF THIS PART IS TO DEMONSTRATE THAT WHEN THE TOOL CHANGEOVER HAS BEEN ORGANIZED SIMPLE IMPROVEMENTS CAN GAIN A LOT OF TIME WITHOUT ANY LARGE INVESTMENT BEING NECESSARY. THE FOLLOWING IDEAS MAY BE PRODUCED USING THE ACCESSORIES CONTAINED IN THE TRAINING KIT: REPLACE THE TOOL’S TIGHTENING SCREW WITH A WING NUT SCREW (ELIMINATES No. 13 WRENCH). USE A 10 MM THICK U-SHAPED WASHER TO MAKE THE CLAMP ARM HEIGHT SETTING (ELIMINATES 10 MM SCREWING ELEMENT. REPLACED BY ¼ TURN, ELIMINATES ADJUSTMENT & INSPECTION OF CLAMP ARM HEIGHT. REPLACE THE TOP NUT ATTACHING THE CLAMP ARM TO THE THREADED ROD BY A WING NUT (ELIMINATION OF No. 17 WRENCH. MARK THE POSITION OF BOTH TOOLS WITH A PENCIL FOR PRE-SETTING PURPOSES.

- TRAINING COURSE IMPLEMENTATION - TIME MEANS USED TRAINING SESSION IMPLEMENTATION ADVICE/COMMENTS/NOTES FOR TRAINER 40s TO 1m 3 RD TIMING: LOW COST TECHNICAL MODIFICATIONS CONCLUSION: ONCE AGAIN, THE TIME HAS BEEN MORE THAN HALVED WITHOUT INVOLVING LARGE INVESTMENTS. NOW STUDY MORE COSTLY IMPROVEMENTS & IMPLEMENT THEM. ASK THE GROUP IF THIS RESULTS IN CHANGES TO THE CHANGEOVER PROCEDURE. IF THIS IS THE CASE, MAKE THE NECESSARY MODIFICATIONS. A MODEL CHECKLIST & POSSIBLE CHANGEOVER PROCEDURE AT THIS LEVEL ARE AMENDED. DO NOT FORGET TO TIME THIS EXERCISE. USING THE ACCESSORIES CONTAINED IN THE TRAINING KIT, THE FOLLOWING MAJOR MODIFICATIONS CAN BE MADE. USE THE INTERCHANGEABLE MATERIAL STORES (COLLARD PIN). ONE STORE REPLACES THE SUPPORT PIN ON THE HOLE T2 WHILE THE OTHER IS RELOADED WITH MATERIAL EXTERNALLY (WHILE THE MACHINE IS STILL RUNNING E.G. INTERCHANGEABLE MAGAZINE) THE MATERIAL STORES CHANGEOVER IS MADE BY SIMPLY SWITCHING OVER THE TWO STORES WITHOUT STOPPING THE MACHINE. STANDARDIZATION OF THE HEIGHT OF THE TOOLS USING ADAPTORS (THIS STANDARDIZATION MAKES IT NOT NECESSARY TO USE THE U-SHAPED WASHER). STANDARDIZATION OF THE DIAMETERS OF THE TOOLS BASES BY MEANS OF ADAPTORS & ELIMINATION OF POSITIONING SETTING BY USING TWO LOCATION ALIGNMENT PINS IN HOLES T3 & T4 ON WHICH TOOLS BASES ARE PLACED DIRECTLY IN ABUTMENT.

- TRAINING COURSE IMPLEMENTATION - TIME MEANS USED TRAINING SESSION IMPLEMENTATION ADVICE/COMMENTS/NOTES FOR TRAINER 40s TO 1m 4 TH TIMING: MAJOR TECHNICAL MODIFICATIONS CONCLUSION: MORE TIME HAS BEEN GAINED, BUT THE GAIN IS LESS CONSIDERABLE. SOME IMPROVEMENTS WILL THEREFORE NOT BE PROFITABLE AT THIS POINT HOWEVER, WHILE THESE MODIFICATIONS DO NOT PROVE PROFITABLE AT THIS POINT, THEY MAY DO SO FOR FUTURE DIES. THIS MEANS THAT ALL CASES THESE IMPROVEMENTS MUST BE INCLUDED IN THE SPECIFICATION FO FORTHCOMING DIES (STANDARDIZATION) WORKING IN PARALLEL (ADDING ONE PERSON) ASK THE GROUP IF THE CHANGEOVER TIME CAN BE IMPROVED STILL FURTHER BY ADDING ONE PERSON TO THE CHANGEOVER. REDEFINE THE CHANGEOVER PROCEDURES. DO NOT FORGET TO TIME THIS EXERCISE SEQUENCE. AFTER THE PARTICIPANTS HAVE JUST SEEN, DO THEY THINK THEIR DIE CHANGEOVER IS PERFORMED AS EFFICIENTLY AS POSSIBLE?

- TRAINING COURSE IMPLEMENTATION - TIME MEANS USED TRAINING SESSION IMPLEMENTATION ADVICE/COMMENTS/NOTES FOR TRAINER 3s TO 4s 5 TH TIMING: ADDING ONE PERSON SLIDES 5 & 6. PHASE 2 OF THE SMED METHOD IMPROVING IT IS MORE INTERESTING TO COVER THE ADDITION OF STAFF AT THIS LEVEL DURING THE TRAINING COURSE, AS THE RESULT IS FAR MORE VISIBLE AT THIS STAGE. DURING THE ORGANIZATION PHASE 20 OR 40 SECONDS WOULD HAVE BEEN GAINED REPRESENTING A GAIN OF 20%, WHILE ADDING ONE MORE PERSON AT THIS STAGE THE CHANGEOVER IS ONCE AGAIN HALVED. HOWEVER, ON A REAL WORKSTATION, THIS ISSUE WILL HAVE TO BE ADDRESSED AS OF THE ORGANIZATION PHASE. THESE SLIDES RECALL WHAT WAS DONE DURING THIS IMPROVEMENT STAGE: AN ATTEMPT WAS MADE TO OPTIMIZE EACH TOOL CHANGEOVER ELEMENT BY ASKING 3 QUESTIONS: CAN THIS ELEMENT BE ELIMINATED? CAN THIS ELEMENT BE EXTERNAL BY MODIFYING IT? HOW CAN THIS OPERATION (ELEMENT) BE REDUCED? EACH ELEMENT CAN BE IMPROVED USING 5 APPROACHES: 1. PREPARATION OF OPERATIONS (CHECKLIST) 2. ELIMINATION OF UNNECESSARY SETTINGS/ADJUSTING 3. RATIONALIZATION OF HANDLING & TIGHTEN MEANS 4. STANDARDIZATION (WRITTEN DOCUMENTARY FORM) 5. SYNCHRONIZATION OF TASKS (PARALLEL TASKS)

- TRAINING COURSE IMPLEMENTATION - TIME MEANS USED TRAINING SESSION IMPLEMENTATION ADVICE/COMMENTS/NOTES FOR TRAINER SLIDE 7. COMPARISON OF THE TIME GAINED AFTER IMPLEMENTING THE VARIOUS TYPES OF IMPROVEMENT SEEN DURING THE COURSE OF THE EXERCISE. RETURN TO THE TIME MEASURED FOR EACH SEQUENCE & ADD THEM TO THE PREVIOUS SLIDE. ASK PARTICIPANTS TO COMMENT ON THIS GRAPH SLIDE 8. A SMED PROGRAM CAN BE BROKEN DOWN INTO 5 MAIN PHASES SLIDE 9. THE ‘MUSTS’ OF A SMED PROGRAM COMMENT: THE GRAPH DEMONSTRATES THAT AN IMPORTANT PART OF TIME SAVING IS DUE TO ORGANIZATION (5S) & EASILY IMPLEMENTED MODIFICATIONS. BY COMPARISON, COSTLY MODIFICATIONS PRODUCE TIME GAINS WHICH ARE HOWEVER SLIGHT IN RELATION TO THOSE GAINED PREVIOUSLY. IT IS THEREFORE INDISPENSABLE, BEFORE DOING ANYTHING ELSE, TO WORK IN THE ORGANIZATION OF THE PRODUCTION CHANGEOVER BEFORE UNDERTAKING ANY INVESTMENT. REMINDER OF THE CHRONOLOGICAL ORDER OF THE SMED METHOD. EMPHASIZE THE FACT THAT THIS IS THE APPROACH WHICH WILL HENCEFORTH BE USED TO IMPROVE PRODUCTION CHANGEOVER ON THE MACHINE ON WHICH PARTICIPANTS WORK. THIS CONSISTS OF A FEW TIPS TO MAKE SMED A SUCCESSFUL PROGRAM.

- TRAINING COURSE IMPLEMENTATION - TIME MEANS USED TRAINING SESSION IMPLEMENTATION ADVICE/COMMENTS/NOTES FOR TRAINER SLIDE 10. COMPARISON WITH THE FIRST TIMING TO CONCLUDE, A COMPARISON WITH THE FIRST TIMING MAY BE MADE. THIS IS A VERY GOOD EXAMPLE OF SMED, ESPECIALLY BECAUSE IT REQUIRES EXTENSIVE ORGANIZATION ASK THE GROUP HOW IT WAS POSSIBLE TO CHANGE 4 TIRES IN 7 SECONDS ON A RACING CAR WHEREAS IT TAKES 30 MINUTES TO CHANGE ONE TIRE OF A PRIVATE CAR. RECORD ALL THE SUGGESTIONS MAKE BY THE GROUP ON THE FLIP CHART & CATEGORIZE THESE SUGGESTIONS USING THE 5 APPROACHES MENTIONED PREVIOUSLY. THIS IS USED TO ILLUSTRATE EACH APPROACH. THIS EXAMPLE CAN ALSO BE USED TO ILLUSTRATE THE 5 APPROACHES USED TO IMPROVE EACH ELEMENT OF THE PRODUCTION CHANGEOVER. EXAMPLES OF ILLUSTRATING THE 5 APPROACHES BASED ON F1: ELIMINATION OF UNNECESSARY SETTINGS & TRIAL & ERROR: THE POSITION OF WHEELS & THE TIRE ARE MARKED ON THE GROUND. THE CAR STOPS WHEN IT RESTS ON THE JACK. STANDARDIZATION OF MEANS: USE OF IDENTICAL TOOLS FOR DIFFERENT OPERATIONS. IN THIS CASE, A COMPRESSED AIR GUN FITTED WITH A MAGNET MAKES IT POSSIBLE TO VOID HANDLING THE NUB BETWEEN UNSCREWING & RE-TIGHTENING. RATIONALIZATION OF HANDLING & TIGHTENING MEANS: JUST ONE ATTACHMENT POINT IS REQUIRED FOR EACH WHEEL INSTEAD OF 5 FOR A PRIVATE CAR. SYNCHRONIZATION OF TASKS: THE ENTIRE CHANGEOVER IS PERFORMED BY 7 OR 8 PEOPLE EACH OF WHOM CARRIES OUT A VERY SPECIFIC TASK FOR 7 SECONDS. - PREPARATION OF OPERATIONS: THE TIRES ARE PRE-HEATED (EXTERNAL) & PLACED AT A VERY PRECISE LOCATION A FEW MINUTES BEFORE THE CAR ARRIVES FOR TIRE CHANGE.

- APPENDIX 1 - CHANGEOVER PREPARATION CHECKLIST THE EQUIPMENT OPERATOR HAS AT HAND BEFORE THE TOOL CHANGEOVER THE FOLLOWING: 1 MEASURING CALIPERS (TURNED ON AND SET TO INCH SIZE MEASUREMENT 1 9/16" OPEN ENDED WRENCH 1 9/16" CLOSED ENDED WRENCH 1 3/16" ALLEN WRENCH IN-GOING TOOL PART # 2 PREPARED AND READY IN-GOING TOOL PART # 2 MATERIAL STORES READY (LARGE WASHERS) ELEMENTS OF THE CHANGEOVER PROCEDURE THE OPERATOR IS TO MEMORIZE: ADJUST THE HEIGHT & TIGHTEN THE CLAMP ARM BEFORE TIGHTENING THE TOOL TIGHTENING BOLT TO PREVENT THE TOOL MOVING. ADJUST THE TOOL’S POSITION IN RELATION TO THE TWO PERPENDICULAR LEFT & RIGHT EDGES OF THE MACHINE PLATEN. TOOL PART # 1 IS: 2.0225” OF EACH SIDE OF THE TOOL TO THE LEFT & RIGHT EDGES OF THE MACHINE PLATEN & 1.5600” TO THE FRONT EDGE OF THE MACHINE PLATEN. TOOL PART # 2 IS: 1.5225” TO EACH SIDE OF THE TOOL TO THE LEFT & RIGHT EDGES OF THE MACHINE PLATEN & 0.5600” TO THE FRONT EDGE OF THE MACHINE PLATEN. THE DISTANCE BETWEEN THE TOP OF BOTH TOOLS TO THE BOTTOM OF THE CLAMP ARM IS: 0.3120” (+/- 0.0395”)

- APPENDIX 2 - ELEMENTS OF THE TOOL CHANGEOVER TIME (SEC.) SUGGESTED IMPROVEMENTS - LOOSEN THE TOOL USING A 9/16” OPEN/CLOSED ENDED WRENCH 5 USE A WING SCREW TIGHTEN USING A CAM SYSTEM HYDRAULIC CLAMP - REMOVE THE TOOL 3 - PUT THE IN-GOING TOOL ON THE MACHINE PLATEN 5 ADJUST & TIGHTEN THE CLAMP USING 9/16” OPEN/CLOSED ENDED WRENCH ADJUST THE POSITION OF TOOL 80 USE A WING NUT HYDRAULIC CLAMPING USE A U-SHAPED DISTANCE GAUGE TO COMPENSATE FOR THE DIFFERENCES IN TOOL HEIGHTS STANDARDIZATION OF THE HEIGHT OF EXISTING TOOLS STANDARDIZATION OF TOOL DIAMETER & ADDITION OF 2 CENTERING LOCATION DOWEL PINS TO CORRECTLY ALIGN THE EXISTING TOOLS - TIGHTEN THE TOOL USING 9/16” OPEN/CLOSED ENDED WRENCH 10 LOOSEN TOOL USING 9/16” WRENCH - REMOVE THE MATERIAL STORES 20 INTERCHANGEABLE STORES (MAGAZINE SYSTEM & INTERNAL TO MACHINE OPERATION) SYNCHRONIZATION OF TASKS (1 OPERATOR CHANGES OUT THE MATERIAL STORES WHILE THE OTHER CHANGES THE TOOL). INSPECTION 35 - INSPECTION ELIMINATION THANKS TO THE VARIOUS STANDARDS ESTABLISHED.

- APPENDIX 3 - CHANGEOVER PREPARATION CHECKLIST TOOLS PREPARED HAND TOOLS PREPARED POSITION DIMENSION OF TOOLS: TOOL PART # 1 0.3120” (+/- 0.0395”) TOOL PART # 2 0.3120” (+/- 0.0395”) - MATERIAL STORES: FILLED CONTAINER & STORED POINT OF USE TOOL CHANGEOVER PROCEDURE (FROM TOOL PART # 1 TO TOOL PART # 2) UNCLAMP THE TOOL (1/4 TURN) REMOVE OUT-GONG TOOL LOOSEN CLAMP ARM (1/4 TURN) REMOVE U-SHAPE DISTANCE GAUGE & PUT IT ON THE SIDE OF THE MACHINE (5S) TIGHTEN THE TOOL CLAMP (1/4) PUT THE TOOL ON THE MACHINE PLATEN ADJUST THE SIDE POSITION DIMENSIONS TIGHTEN THE TOOL (1/4 TURN) REMOVE THE OUT-GOING TOOL MATERIAL STORES FROM THE SUPPORT POST & PUT IT IN THE EMPTY CONTAINER PUT THE IN-GOING TOOL MATERIAL STORES ON THE MATERIAL STORES SUPPORT POST CHECK THE POSITION DIMENSIONS (OPERATION PERFORMED BY THE SUPERVISOR)

Smed Training Model Trainer Instructions[1]

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Smed Training Model Trainer Instructions[1]