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Time (Total on the part)
Total Machining time: 75 minutes
Chamfering Tool
Milling Cutter
Reduction in time: 12 minutes per products
Total machining time: 63 minutes per product
After failure of the bigger cutter, new cutter was introduced with different specifications. Usage of new cutter produced lesser noise and effective operation.
Summary of the result
Rough Mill
Finish Mill
Operations involved
Drilling
Boring
Milling
Time (total on the part)
Total Machining time: 80 minutes
Tools used
Finish tool
Single tool with different inserts
The result
Reduction in time: 15 minutes per product
Total machining time: 65 minutes per product
Signature of tool signature was changed in order to increase the tool travel and remove the CNC redundant commands in order to do the turning operation in optimum time.
Rough tool
Contains mainly turning operation
Finishing
Roughing
Time (total on the part & total on one hole)
Total Machining time/hole: 3,30min
Total Machining time: 28 mins
The tools used for the holes were:
Flat bottom Drill
8.55mm Carbide Drill
Single tool
The Result
Time reduce/hole: 1,5mins
Total machining time:13 mins! (Reduction by 15mins)
The Reason for using a Single Tool
The 3 tools had overlapping paths (overlapping was during change of the tools the tool went all the way down and came up to switch tools, the coming up was the redundancy) therefore combining the tools reduced tool path and therefore
Summary of the Result
Central Drilll
Slot Drill
They used 4 tools for the 4 operations
The drawing contains 8 holes with 4 operations on each hole
Onsite Inspection of every machine is important in SMED because:
The founder of SMED started the process with Genchi Genbutsu
Employee can be organised
inorder to reduce time employees reduce quality which is not desirable
What is Genchi Genbutsu?
Subtopic
Many firms hold Kaizen meets to reduce SMED
Many firm need to meet the changing demand of the current world, therefore they need to change and thus Kaizen is used to change the production time in SMED
What is kaizen?
The change for the good
Why is it important when applying SMED
keeping the right mechanical tools sorted can help you with reducing the time.
Easier observation because of 5S
SMED is a very complex process, and if we don't apply 5S principle everything will get messy.
What is 5S?
Everything has a place and a place for everything, this is a cleaning too to keep your work environment health and in order using these 5 s
Toyata and SMED -https://bit.ly/2TG7agn
The Effect of SMED on Benefits Gained in Maquiladora Industry -https://bit.ly/38h62nw
Article on applying SMED in Turret punching machine-https://bit.ly/30ANXya
This is a simple video of a father changing the diaper of his child, it is a simple understanding of what SMED is.
In this video we the practical industrial application of how dies are being changed without the application of SMED and then with the application of SMED the amount of time reduced
In this short video we learn that
SMED converted large changeover time of 4-6 hours to single minute exchanges!
There are 6 steps to make this happen:
Repeat 3-4 steps continuously
Reduce the time of exertenal activity
Reduce the time of internal activities
Change internal to external - Reduce waste
observe the process
External process
changes when the machine is running
Internal process
changes when the machine is not operating
Start with 5S
nowadays the costumers are demainding smaller batches and higher frequency meaning we have to minimise the waste in the process
We require SMED when changing from product A to product B on a machine this is called changeover
