How to implement SMED in 3 days? Step By step approach in implementing Quick Change-over

Introduction: We have conducted a 3-day workshop on SMED at JK Tyres, Chennai plant  in 2018, focusing on the bottleneck machine’s change overtime reduction. The bottleneck machine was identified and the current change-over-time was around 23 minutes and the target was to reduce it to less than 10 minutes

Our Activities:

Day 1: Initial Training on SMED, Video Shoot of the current Changeover, Analysis of the changeover and Training the team on Internal and External Activities

Day 2: More than 20 kaizens were identified and the teams started implementing the kaizens. Clear Changeover procedure was created and the teams started preparing for the changeover

Day 3: We had a trial of the changeover and we completed in 16 mins. Minor hiccups were addressed and later we reduced the changeover time to 12 mins

Result: Machine Availability was increased by 160 mins per shift (more than 2.5 hours per shift) and that has boosted the productivity of the unit