Single minute exchange of die

Posted on 31/05/2022 by gembaAdmin22

In this blog we will be learning about SMED and how to implement it.
The basic principle of Lean manufacturing is to increase the competitiveness of
companies by reducing costs. This philosophy seeks to get as close to the optimum as
possible, that is, to spend only what is indispensable of what adds value to the product.
In this sense the Lean manufacturing simply intends to remove all the possible waste.
The principles of Lean are all focused on process improvement, which ultimately leads
to improved efficiency and this leads to higher profitability. One of the building blocks of
Lean relates to the rapid setup. The faster the setup times, the less equipment
downtime since waiting is part of the seven Muda (waste) of a production environment.

What is SMED

SMED is a set of techniques belonging to Lean manufacturing that aim to reduce the
setup time of a machine. When properly applied, it allows machines to take less time to
attach, giving more flexibility to the line.
SMED, also known as Quick Changeover of Tools, can be applied in any industrial unit
and to any machine. It is defined as the minimum amount of time necessary to change
the type of production activity. Thus, it takes into consideration the moment in which the
last piece of a previous lot was produced vis-à-vis the first piece produced by the
subsequent lot (Shingo, 1985).

Why the SMED is required?

From the above example we can see that when our lot size increases, production to
operation time ratio decreases. But in this highly competitive market era every company
wants to increase the variety of products and wants to minimize the lot size as much as
possible.
So, for the small lot size it is necessary that the die changeover time should be not high
other wise it effects the production time and the cost of the product.

Steps in SMED

Observing and Recording.
Separation between internal and external tasks.
- Internal tasks: activities performed during the change operation while the
  machine is in downtime.
- External Tasks: activities performed before the change operation, not made in the downtime period.
Converting the maximum number of internal tasks into external tasks. Streamlining all the possible tasks.
Documenting internal and external procedures.

Phases in SMED

10 steps to choosing a warehouse management system

Aside

Choosing the right warehouse management system can often be as simple as taking a few considerations into account:

Step 1. Understand your current systems

If you are already using software to manage your warehouse operations or part of your warehouse operations, then you should start by looking at it in detail. What functions does it have that you like? What functions does it not have that you want?

You will also need to know what integrations you require from your warehouse management system. For example, you may require it to integrate it with your shipping carriers or sales channels.

Step 2. Decide if your picking process requires a WMS

If you are running a very small ecommerce operation, like a side-hustle, a WMS is unlikely to be necessary. But, if you are moving any reasonable number of products or you have any ambitions to scale you will need a more sophisticated solution.

Step 3. Understand what you are looking for in a warehouse management system

This is where you make your checklist of ‘must-haves’ and ‘like-to-haves’. You can then compare this list against your options.

Step 4. Decide on your budget

Of course, good warehouse management systems will cost money. So you will need to know how much money you can commit from your cash flow to purchasing one.

Step 5. Create a shortlist

There will be a few different options you can choose from. The easiest way to decide which ones to shortlist is simply to create a list or spreadsheet listing prices and features.

Once you have created a shortlist you can then go and use free trials or book demos with those you think are right for you.

Step 6. Check it integrates with your entire fulfillment process

Warehouse management is only part of the puzzle of ecommerce. Your WMS should also connect with your inventory management system and shipping carriers.

Step 7. Check it gives you the reports your need

A good warehouse management system will give you reports that can make definite improvements to your business. It should provide these reports in an easily accessible way.

It’s also good if the WMS provides demand forecasting as this will help prevent under and overstocking in the future.

Step 8. Check it works with your ecommerce tech-stack

You probably use a range of platforms, marketplaces, sales channels and shipping carriers. You need to check that your warehouse management system either has a native integration, seamless workaround or open API to do this.

This is where you can make use of a free trial. As it’s hard to know if a system works for you without testing it out.

Step 9. Is it easy for pickers to use and understand?

A good WMS will be easy for your pickers and warehouse team to understand and use. While there will always be a training period with any new software, you should look for an intuitive interface and easy-to-understand processes. This will make it easier for your team to pick up the new system and cut down on training time for new hires.

Step 10. Does it come with support?

Your business will be unique, therefore it’s important that any service you purchase comes with support. This support will be able to help you through any issues that arise with the product.

Article by:- Akshay Patel

Total Quality Management (TQM)

Aside

Let us first understand what is TQM and after that we will look into its 4 major pillars which helps us in TQM for achieving desired results.

Total = Made up of the whole.
Quality = Degree of excellence of a product or service provides.
Management = Art of Planning, Organizing, Controlling etc.

TQM can be further divided into 3 parts as follows

System = All persons of all divisions at every stratum.
Method = In methods there are different tools and methods which are used to
achieve desired result such as Kaizen, QC Circle, 5S, TPM, MSA, OEE etc.
Purpose = Purpose can be any of the following from (QCDSME).
▪ Q: Quality improvement
▪ C: Cost reduction
▪ D: Delivery execution
▪ S: Safety maintenance
▪ M: Morale boosting
▪ E: Environmental protection

TQM can be defined as a management approach for an organization, centred on quality, based on the participation of all its members and aiming at long-term success through customer satisfaction, and benefits to all members of the organization and to society. And the main motive of TQM is to “Do the right things right the first time, every time”

❖ 4 Pillars of TQM

Customer Focus: Studying customer needs, gathering customer requirements, and measuring and managing customer satisfaction. Customer satisfaction is seen as the company’s highest priority. The company believes that it will only be successful if its customers are satisfied.
Process Management: Develop a production process that reduce the product variations. Applying the same process; the same product should be produces with the same level of quality every time. Teams are process-oriented, and interact with their internal customers to deliver the required results. Management’s focus is on controlling the overall process, and rewarding teamwork.
Employee Empowerment: TQM environment requires a committed and well trained work force that participates fully in quality improvement activities. Ongoing education and training of all employees supports the drive for quality.
Continuous Improvement: TQM recognizes that product quality is the result of process quality. As a result, there is a focus on continuous improvement of the company’s processes. This will lead to an improvement in process quality. In turn this will lead to an improvement in product quality. Measurement and analysis id the tool that has been used for that

Article By.

Dhavalkumar Gohel