The SMED Machine

THE SMED MACHINE

By João Paulo Pinto for CLT VALUEBASED SERVICES, 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.

THE SMED MACHINE © 2015

PROCESS 6 Plug Sub D25 TO PREPARE THIS MACHINE IN ORDER TO PRODUCE PROCESS 5 Plug Sub D9

Zero Force Connector

QUALITY PRODUCTS YOU NEED TO SUCCESSFULLY PROCESS 1

EXECUTE SEVEN PROCESSES (STEPS).

PROCESS 4 DIP Switch

GOOD LUCK! PROCESS 3 Pulse switch

PROCESS CONCLUDED WITH SUCCESS

TIMER

GENERAL TIMER

ERROR SIGNAL

GENERAL SWITCH

THE PROCESSES “Fall seven times. Stand up eight.”

READY TO MAKE YOUR FIRST CHANGEOVER?  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

PROCESS 1

 To prepare this process you need to prepare the ZFC40 (Zero Force Connector) so that energy can flow to 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

PROCESS 2  This DIL (dual inline) connector needs to be fit so that the energy can flow to the next process;

 This is the right sequence to prepare this process:

DGIKab

THE SMED MACHINE © 2015

JUST TO REMEMBER THE ALPHABET…

THE SMED MACHINE © 2015

PROCESS 3  In this process two pulse buttons need to be pressed. It is quite simple!

THE SMED MACHINE © 2015

PROCESS 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

PROCESS 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

PROCESS 6  Now it is time to prepare the 6th process: Plug Sub D25!

ERROR!

 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…

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

PROCESS 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

DID YOU MANAGE TO PUT IT WORKING? Good, it is now time to improve it… and document it as well

THE SMED MACHINE © 2015

LET’S ANALYSE THE RESULTS 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

 Main improvements made?  Lessons learned?

THE SMED MACHINE © 2015

_______ min

THANK YOU SO MUCH FOR YOUR ATTENTION

JOﾃグ PAULO PINTO, Eng mgt@cltservices.net +351.936.000.079 www.cltservices.net THE SMED MACHINE ﾂｩ 2015