the smed machine
DESCRIPTION
We have devised a machine that simulates the Changeover process. This machine is used as a pedagogic tool to teach the SMED Method. It is a part of a training course that we execute in industrial firms and seminars. For more information on this machine or the SMED process call us: +351.936.000.079TRANSCRIPT
THE SMED MACHINEBy João Paulo Pinto for CLT VALUEBASED SERVICES, 2015 ©
THE SMED MACHINE © 2015
THE MACHINE ITSELF
It was designed by CLT and build by IOnline;
It was conceived to put the concepts of quick changeover into practice.
TO PREPARE THIS MACHINE IN ORDER TO PRODUCE
QUALITY PRODUCTS YOU NEED TO SUCCESSFULLY
EXECUTE SEVEN PROCESSES (STEPS).
GOOD LUCK!
PROCESS 3
PROCESS 4
PR
OC
ESS
1
PROCESS 5
PROCESS 6
Zero
Fo
rce
Co
nn
ect
or
Plug Sub D25
Plug Sub D9
DIP Switch
Pulse switch
GENERAL SWITCH
PR
OC
ESS
CO
NC
LUD
ED W
ITH
SU
CC
ESS
ERROR SIGNAL
GENERAL TIMER
TIMER
THE PROCESSES
“Fall seven times. Stand up eight.”
THE SMED MACHINE © 2015
R E A D Y T O M A K E Y O U R F I R S T C H A N G E O V E R ?
Make sure the timer is on;
You may need some tools to help you;
Take notes along the changeover;
Record ideas that may help us to reduce complexity and setup time.
Take some pictures that may be used as future memory;
Discuss the solutions and implement them;
Discuss the results!
THE SMED MACHINE © 2015
P R O C E S S 1
To prepare this process you need to prepare the ZFC40(Zero Force Connector) so that energy can flowto Process 2;
To do so, keep this code in mind, you will need it to make energy flowing:
2 3 9 14 17 Off you go!
THE SMED MACHINE © 2015
P R O C E S S 2
This DIL (dual inline) connector needs to be fit so that the energy canflow to the next process;
This is the right sequence to prepare this process:
D G I K a b
THE SMED MACHINE © 2015
JUST TO REMEMBER THE ALPHABET…
THE SMED MACHINE © 2015
P R O C E S S 3
In this process two pulse buttons need to be pressed. It is quite simple!
THE SMED MACHINE © 2015
P R O C E S S 4
This processes uses a DIP Switch that needs to be prepared.
The operations manual of this machine had a missing page in this process so you need to find the position of only two switches…
1on, 2off, 3off, 4on, 6on, 8on.
THE SMED MACHINE © 2015
P R O C E S S 5
Plug Sub D9
This the simplest process as only one plug needs to be involved;
Why don’t you give it a try?
THE SMED MACHINE © 2015
P R O C E S S 6
Now it is time to prepare the 6th process: Plug Sub D25!
To work properly you need a key to be inserted in this process;
The key can not be directly inserted in the Plug Sub D25;
You need to prepare a “bridge” so it can work properly;
Use the materials provided to do so…
ERROR!
THE SMED MACHINE © 2015
The “blue wires” are to be consumed during the process,
ie: every time you need to prepare this process new wires
need to be mounted…
THE SMED MACHINE © 2015
P R O C E S S 7
After successfully concluded the previous six processes this machine gives you a limited amount of time to prepare the seventh process;
If you fail to setup this process you need to start all over again from process 1 to 6;
This process was normally prepared by an old lady that is now retried and no one knows exactly how she managed to put the process right. Maybe it was her experience or the feminine intuition…
The next picture depicts one rare moment of the process well prepared and have been used ever since as a guide/reference to prepare this process.
THE SMED MACHINE © 2015
Consider this the “correct position” of
the POTENTIOMETERS
THE SMED MACHINE © 2015
D I D Y O U M A N A G E T O P U T I T W O R K I N G ?
Good, it is now time to improve it…
and document it as well
THE SMED MACHINE © 2015
L ET ’ S A N A LY S E T H E R E S U LT S
INITIAL SETUP:
TOTAL TIME TO PREPARE THE MACHINE: _______ min
TOTAL RESETS _______
COMMENTS, SUGGESTIONS AND WHAT CAN BE CHANGED?
[…]
FINAL SETUP:
TOTAL TIME TO PREPARE THE MACHINE _______ min
Main improvements made?
Lessons learned?
THE SMED MACHINE © 2015
T H A N K Y O U S O M U C H F O R Y O U R AT T E N T I O N
JOÃO PAULO PINTO, Eng
+351.936.000.079
www.cltservices.net