By Shigeo Shingo, Andrew P. Dillon
Written by means of the commercial engineer who built SMED (single-minute alternate of die) for Toyota, A Revolution in Manufacturing presents an entire review of this strong just in time creation instrument. It deals the main whole and exact directions to be had anyplace for remodeling a producing atmosphere in ways in which will accelerate creation and make small lot inventories possible. the writer delves into either the speculation and perform of the SMED method, explaining basics in addition to suggestions for utilizing SMED. The seriously acclaimed textual content is supported with thousands of illustrations and pictures, in addition to twelve chapter-length case experiences.
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Additional resources for A Revolution in Manufacturing: The SMED System
As a result, efficient setups require highly skilled workers, and although a simple machine may pose no problems, the specialized knowledge of a "setup engineer" (sometimes referred to simply as a "setup man") is called for when the machinery is complex. While the setup engineer is engaged in the setup, the machine operator normally performs miscellaneous duties as the engineer's assistant, operates another machine, or in some cases simply waits. All of these activities, however, are inefficient.
Setup time decreased, and the number of trial shots was reduced. With resins, as with metals, defective items can sometimes be crushed and reused, but this is not satisfactory, because it leads to a deterioration in quality. It is always preferable to manufacture quality goods from the start and to avoid producing substandard goods altogether. In another case, molds for a mid-sized plastic molding machine were preheated simply by passing warm water through a coolant hose. A mobile steam generator was moved next to the molds to generate the warm water.
When lot size is increased by another factor often, however, to 10,000 units, the related decrease in man-hours is only 17%. In other words, increasing the size of a small lot leads to a relatively large decrease in man-hours, but as size increases the rate of reduction in man-hours decreases. Similarly, the gains from increasing lot size are greater for long setup times than for shorter ones (Table 2-2). Despite this law of diminishing returns, the rate of reduction rises whether the setup time is four hours or eight.