About the Topic:
SMED is single (digit) minute exchange of dies for optimizing setup time with a rapid and efficient way of converting a process from running the current product to running the next product”
SMED increases flexibility to respond to meet customer requirement & about the standardization of optimized process
Poka-Yoke is a technique that either prevents a mistake from being made or makes the mistake obvious at a glance (Restricting errors at source). In simple it is a technique for avoiding human errors at work. This helps people and processes work right the first time, which makes mistakes impossible to happen.
Poka Yokes perform a detective function, eliminating defects in the process as early as possible. This approach to production fits perfectly the culture of continuous improvement.
Contents of the Topic:
- Selection of Model Machine for optimizing setup/change over time by analyzing data
- Understanding the method to record the setup (Video camera) to analyze every setup step & Define Setup optimization participants & assign tasks
- Brainstorming (Developing ideas & solutions) & analyzing the whole setup with the team in classroom/conference room with standard sheet
- Understand the steps of SMED for optimizing setup/changeover time
- Implementation of actions defined in the action tracker
- Creating a standardized setup sequence as per revised/improved process
- Understanding Poka-Yoke/Mistake proofing for zero defects
- Poka-Yoke principles
- Poka-Yoke concepts
- Poka-Yoke methods
- Poka-Yoke examples
Benefits of the Topic:
Significant gains in the following objectives in Delivery, Quality, Cost, Motivation as follows,
- Reduction in changeover /setup time by 40+%
- Reduction in setup cost by 15+%
- Inventory reduction by 30+%
- Reduction in batch size & a significant reduction in throughput time by 20+%
- A standardized process for changeover /setup (Optimized sequence)
- Lower skill requirement for changeover/setup process
- Empowered motivated staff & workforce
- Poka-Yoke - Elimination of Sources of defects (0% Errors)
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