Photos 24-Jul

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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