【正文】 ity ? Higher Productivity Waste Elimination ? Safer Changeovers ? Less Inventory ? Standardization Batch Size Lead Time Reduction SMED: Example 1 Internal External Close coolant cover all hydraulic valves Prepare next die Detach coolant hoses Put tools in order Remove knockout joint clamping nuts Prepare pallet for castings Loosen tie bar Remove clamps on movable die Raise die with hoist Remove knockout joint Remove clamps on fixed die With hoist, remove die from machine With hoist, insert die from machine Align sleeves (use jig) Attach fixed jig clamps Attach knockout joint Tighten knockout joint, attach nuts Attach movable die clamps Attach coolant hoses Adjust die closing force Preheat, set operation conditions Separating Internal External SMED: Example 1 Setup Steps before SMED Improvement after SMED Internal Setup 1 Close coolant cover all hydraulic valves Turn off coolant water before last shot。 standardize bolt diameters 8 Raise die with hoist Set at specific location in external setup 9 Remove knockout joint (same as 5) 10 Remove clamps on fixed die (same as 7) 11 With hoist, remove die from machine Time reduced by joint use of horizontal die insertion rack hoist 12 With hoist, insert die from machine (same as 11) 13 Align sleeves (use jig) Time reduced with die standardization and positioning 14 Attach fixed jig clamps (same as 7) 15 Attach knockout joint (same as 5) 16 Tighten knockout joint, attach nuts (same as 5) 17 Attach movable die clamps (same as 7) 18 Attach coolant hoses (same as 4) 19 Adjust die closing force (same as 6) 21 Preheat, set operation conditions Advance preheating in external setup External 2 Prepare next die 3 Put tools in order 20 Prepare pallet for castings Transferred to External Setup Eliminated Reduced Time SetUp Reduction Form ? Observe the operations and break into small elements ? Document what is really happening during the operation ? Document the needed tools Set Up Reduction Form Example O b se r v e r : Jo e L e a n M o d e l : 12P r o ce ss: B o l st e r R o b o t D a t e : 0 1 Ja n 0 2S t a r t t i m e f o r t h i s sh e e t 0 : 0 0 S h e e t 1 o f 1E l e m e n t D e s c r i p t i o n F i n i s h T i m e S t e p T i m e T o o l s / G a g e s P r o c e s s I n f o O b s e r v a t i o n sL o a d 1 F i x t u r e 1 : 2 3 1 : 2 3C l a m p P a r t 3 : 1 9 1 : 5 6 2 W r e n ch e sC l e a n O i l 4 : 3 0 1 : 1 1 P a p e r T o w e l T h r o w a w a y p a p e r t o w e lS t r i n g e r i n g O p e r a t i o n 1 2 : 2 8 7 : 5 8 W e l d e rR o b o t S t a r t 1 1 4 : 3 0 2 : 0 2F i n i sh P a r t 2 1 9 : 2 9 4 : 5 9U n cl a m p P a r t 2 2 0 : 1 1 0 : 4 2 2 W r e n ch e sW a i t o n H o i st 2 1 : 4 0 1 : 2 9U n l o a d P a r t 2 2 3 : 5 7 2 : 1 7S t e p 123459678P r e K a i z e n P o s t K a i z e nC i r c l e O n e S t e p P r o c e d u r e T i m e T i m e E l e m e n t I n t e r n a l E x t e r n a l1 1 : 1 3 : 2 0I n t e r n a l 1 M a t e r i a l h a n d l e r m o v e t h e t r a ck r o l l e r s o u t o f t h e o p e r a t i o n a r e a s 1 1 : 1 4 : 1 1 0 : 0 0 : 5 1 0 : 0 0 : 5 1I n t e r n a l 2 T a ke o u t t h e T r a ck r o l l e r f i x t u r e f r o m m a ch i n e 1 1 1 : 1 4 : 1 5 0 : 0 0 : 0 4 0 : 0 0 : 0 43 T a ke o u t t h e T r a ck r o l l e r f i x t u r e f r o m m a ch i n e 2 1 1 : 1 5 : 2 4 0 : 0 1 : 0 9 0 : 0 1 : 0 9I n t e r n a l 4 T a ke t h e f i x t u r e t o t o o l b o x 1 1 : 1 5 : 4 3 0 : 0 0 : 1 9 0 : 0 0 : 1 9I n t e r n a l 5 P i ck u p n e w f i x t u r e t o m a ch i n e si t e 1 1 : 1 6 : 4 7 0 : 0 1 : 0 4 0 : 0 1 : 0 4I n t e r n a l 6 b a ck t o t o o l b o x a n d p u t o l d f i x t u r e i n t o t o o l b o x 1 1 : 1 6 : 5 7 0 : 0 0 : 1 0 0 : 0 0 : 1 0I n t e r n a l 7 T a ke t h e n e w f i st u r e t o m a ch i n e I n t e r n a l 8 I n st a l l n e w f i x t u r e o n m a ch i n e 1 1 1 : 1 7 : 5 1 0 : 0 0 : 5 4 0 : 0 0 : 5 4I n t e r n a l 9 T a l k t o su p e r v i so r ( m a y b e so m e p r o b l e m ) 1 1 : 1 8 : 0 4 0 : 0 0 : 1 3 0 : 0 0 : 1 3I n t e r n a l 10 g o t o a n o t h e r m a ch i n e t o g e t se t u p m a n n u a l 1 1 : 1 8 : 4 5 0 : 0 0 : 4 1 0 : 0 0 : 4 1I n t e r n a l 11 U n l o ck co n t r o l b o x , r e se t m a ch i n e b a se d o n m a n n u a l 1 1 : 2 0 : 3 3 0 : 0 1 : 4 8 0 : 0 1 : 4 812 U n l o ck co n t r o l b o x , r e se t m a ch i n e b a se d o n m a n n u a l 1 1 : 2 1 : 3 9 0 : 0 1 : 0 6 0 : 0 1 : 0 613 p u t b a ck m a n n u a l , t a ke a w r e n ch 1 1 : 2 1 : 4 5 0 : 0 0 : 0 6 0 : 0 0 : 0 6I n t e r n a l 14 l o a d f i r st p c o n m a ch i n e 1 1 1 : 2 2 : 2 5 0 : 0 0 : 4 0 0 : 0 0 : 4 0I n t e r n a l 15 ch e ck a n d a d j u st 1 1 : 2 3 : 2 0 0 : 0 0 : 5 5 0 : 0 0 : 5 5I n t e r n a l 16 ca l l m a i n t e n a n ce p e o p l e f o r h e l p d u e t o e l e ct r o n i c p a n e l i ssu e 1 1 : 2 5 : 1 2 0 : 0 1 : 5 2 0 : 0 1 : 5 2I n t e r n a l 17 M a i n t e n a n ce f i x t h e p r o b l e m 1 1 : 2 7 : 4 6 0 : 0 2 : 3 4 0 : 0 2 : 3 4I n t e r n a l 18 o p e r a t o r a d j u st a g a i n 1 1 : 3 0 : 2 8 0 : 0 2 : 4 2 0 : 0 2 : 4 2I n t e r n a l 19 l o a d f i r st p c o n m a ch i n e 2 1 1 : 3 1 : 0 3 0 : 0 0 : 3 5 0 : 0 0 : 3 5E x t e r n a l 20 ch e ck a n d a d j u st 1 1 : 3 2 : 1 4 0 : 0 1 : 1 1 0 : 0 1 : 1 1I n t e r n a l 21 w a l k b a ck t o t o o l b o x , l o o ki n g f o r t o o l 1 1 : 3 4 : 1 5 0 : 0 2 : 0 1 0 : 0 2 : 0 1E x t e r n a l 22 m o v e t h e w o o d p a l l e t t o m a ch i n e a r e a