ABSTRACT
In this chapter, the authors discuss time savings achieved and other effects of applying the Single-Minute Exchange of Die (SMED) system. Cutting setups that used to take two hours to three minutes with SMED, however, changes the situation considerably. The SMED system offers the only path to high-diversity, small-lot production and minimal inventory levels. Implementing SMED increases investment efficiency by making possible dramatic increases in productivity at relatively little cost. If setup times are drastically reduced, then the work rates of machines will increase and productivity will rise in spite of an increased number of setup operations. Setup errors are reduced, and the elimination of trial runs lowers the incidence of defects. Quality also improves, since operating conditions are fully regulated in advance. Simpler setups result in safer operations. The total amount of setup time — including both internal and external setup — is reduced, with a consequent drop in man-hours.
