Dr.N.G.P. Institute of Technology: Department of Mechanical Engineering

Dr.N.G.P.
Institute of Technology
Approved by AICTE, New Delhi & Affiliated to Anna University, Chennai
Recognized by UGC & Accredited by NAAC with A+ and NBA [BME, CSE, ECE, EEE & Mechanical]
Department of Mechanical Engineering

Name of the Faculty : Dr D VASANTH KUMAR
Subject Name & Code : LEAN MANUFACTURING & OIM552
Branch & Department : B.E MECHANICAL
Year & Semester : III & V
Academic Year : 2021 - 2022
Mech/Dr.N.G.P.IT 1
Syllabus
• UNIT I - Introduction to Lean Manufacturing
• UNIT II - Cellular manufacturing, JIT, TPM
• UNIT III - Set-up Time Reduction, TQM, 5S, VSM
• UNIT IV - SIX SIGMA
• UNIT V - Case studies
Mech/Dr.N.G.P.IT 2
Course Outcomes
• CO1 : Demonstrate the principles of lean manufacturing
• CO2 : Analyze the various methods for productivity measurement and

improvement
• CO3 : Apply the tools/techniques of lean manufacturing to industrial
problems
• CO4 : Execute various phases of Six Sigma for real time application
• CO5 : Analyze how lean techniques can be applied to various industry

Mech/Dr.N.G.P.IT 3
Unit 2- Set-up Time Reduction, TQM, 5S, VSM
• Set up time reduction
– Definition
– Philosophies and Reduction approaches.
• TQM
– Principles and implementation
• 5S
– Principles and implementation
• Value stream mapping
– Procedure and principles
Mech/Dr.N.G.P.IT 4
Changeover Defined
• Changeover is the total process of converting a machine or
line from running one product to another
• Changeover time is the total elapsed time between the last
unit of good production of the previous run, at normal line
efficiency, to the first unit of good production of the
succeeding run, at full line efficiency.
5
Traditional approach
• Setup is given and fixed
• Therefore,
– Use highly skilled setup personnel
– Minimize product variety
– Combine lots
– Make large batches
6
Another way
• Setups CAN be improved!
• Small lot production REQUIRES short setups
• Setup time reduction of 90% and more is common
7
Benefits of setup reduction
• Better quality
• Lower cost
– Less inventory
• Better flexibility
• Better worker utilization
• Shorter lead time and more capacity
• Less process variability
8
Classification of setup activities
• Type 1
– Gathering, preparing, and returning tools, fixtures, etc.
• Type 2
– Removing previous setup, mounting next setup on machine
• Type 3
– Measuring, calibrating, adjusting
• Type 4
– Producing test pieces, further adjustment until parts are
good
9
What is SMED?
• Single Minute Exchange of Dies is changing process tooling in 9
minutes or less.
• The process was developed by Shigeo Shingo at Mazda, Mitsubishi
and Toyota in the 1950’s and 1960’s.
– Separate internal and external activities.
– Convert internal activities to external activities.
– Streamline all activities.
10
Single Minute Exchange of Dies
• Internal set-up activities.

Elements in the changeover which can only be done when the machine
is stopped.
• External set-up activities.
Elements that can be performed when the machine is running.
11
Why SMED?
• Reduced inventories.
• Improved productivity.
• Higher quality levels.
• Increased safety.
• Improved flexibility.
• Reduction in throughput time.
• Improve operator capabilities.
• Lower manufacturing costs.
12
SMED Methodology
• Identify internal and external steps
• Convert internal steps to external
• Improve all aspects of the setup operation
• Abolish setup
13
The SMED Process
• Preliminary Stage – Observe and record.

• Stage 1 – Separate internal and external activities.
• Stage 2 – Convert internal activities to external activities.
• Stage 3 – Streamline all activities.
• Stage 4 – Document internal and external procedures.
14
Preliminary Stage
Observe and record

• Team-work
– Recorder
• Overall duration (from last product to first good product).
• Describe the change (from what to what?).
• Record the equipment used.
– Timers
• Time each step
– Fact collectors
• Breakdown the steps into actions – as much detail as possible.
15
Stage 1
Separate internal and external activities.

• Study each internal step and ask if it could be external.
• Common issues:
– Dies in remote storage racks.
– Spanners not available.
– Raw material checks.
– Lifting equipment not available.
16
Stage 2
Convert internal to external.

• Ask why the remaining internal steps can’t be external.
• Re-examine the true function of each step.
• Common issues:
– Cold dies – using material to heat the dies.
– Imaginary center lines and reference planes.
– No record of settings.
17
Stage 3
Streamline all activities.

• Analyze the elements (facts), and discuss all possible ways of
improving the step.
• Study the external activities as well as the internal activities.
• Common issues:
– Fastenings – Are bolts needed? If so remember that only the last
turn tightens a nut or bolt.
– Standardize bolt heads.
– Standardize die heights.
18
Stage 4
Document the procedures.

• Write down the new internal and external procedures.
• Fill in an action sheet to ensure that the new procedures can be
achieved.
• Review the whole activity to determine “What went well?”, “What
went badly?” and three changes that the team would make before the
next SMED activity.
19
The SMED System - Results
Company Machine Before improvement After improvement Red’n
T Manufacturing1 80t single shot press 4 hours 0 mins 4 mins 18 sec 98%
S Metals1 100t single shot press 40 mins 2 mins 26 sec 94%
H Press1 30t single shot press 50 mins 48 sec 98%
TT Industries1 50 oz injection moulding 1 hour 10 mins 7 mins 36 sec 89%

m/c
Expanded Metal Co. 4’6” lath press 4 hours 30 mins 11 mins (note: NOT 96%
SMED)
S Engineering Machining Centre 139 minutes 59 mins 29 secs 57% *
AM Bottlers Bottling plant 32 mins 43 secs 23 mins 33 secs 28% *
E Finishing Paint Plant 56 mins 26 secs 23 mins 12 secs 59% *
Ref 1: Modern Approaches to manufacturing improvement – the Shingo System, Shigeo Shingo, ISBN: 091529964x * After one SMED exercise
20
Mech/Dr.N.G.P.IT 21
Thank You
Mech/Dr.N.G.P.IT 22

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Dr.N.G.P.

Department of Mechanical Engineering

Subject Name & Code : LEAN MANUFACTURING & OIM552

Branch & Department : B.E MECHANICAL

Year & Semester : III & V

Academic Year : 2021 - 2022

• UNIT II - Cellular manufacturing, JIT, TPM

• UNIT III - Set-up Time Reduction, TQM, 5S, VSM

• UNIT IV - SIX SIGMA

• UNIT V - Case studies

• CO2 : Analyze the various methods for productivity measurement and

• CO5 : Analyze how lean techniques can be applied to various industry

• Internal set-up activities.

• Preliminary Stage – Observe and record.

Observe and record

Separate internal and external activities.

Convert internal to external.

Streamline all activities.

Document the procedures.

S Metals1 100t single shot press 40 mins 2 mins 26 sec 94%

H Press1 30t single shot press 50 mins 48 sec 98%

TT Industries1 50 oz injection moulding 1 hour 10 mins 7 mins 36 sec 89%

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