By Shigeo Shingo, Andrew P. Dillon
Written by means of the economic engineer who constructed SMED (single-minute trade of die) for Toyota, A Revolution in production presents a whole assessment of this strong simply in time creation instrument. It deals the main entire and unique directions to be had wherever for reworking a producing atmosphere in ways in which will accelerate construction and make small lot inventories possible. the writer delves into either the speculation and perform of the SMED procedure, explaining basics in addition to ideas for using SMED. The severely acclaimed textual content is supported with thousands of illustrations and pictures, in addition to twelve chapter-length case experiences.
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Extra info for A Revolution in Manufacturing: The SMED System
4min. 4hrs. 1,000 1 min. 1 m i n . + ^ ^ = 1 . 2 4 min. 36 100 4hrs. 10,000 1 min. 1 m i n . + ^ ^ = 1 . 0 2 4 min. 30 83 100 TABLE 2 - 1 . Relationship Between Setup T i m e and L o t Size—I As Table 2-1 shows, increasing the lot size from 100 to 1,000 units leads to a 64% reduction in production man-hours. When lot size is increased by another factor often, however, to 10,000 units, the related decrease in man-hours is only 17%. In other words, increasing the size of a small lot leads to a relatively large decrease in man-hours, but as size increases the rate of reduction in man-hours decreases.
10-000= 1 048 min. 18 71 ) 100 T A B L E 2 - 2 . 5 8 hours 8 x 9 = 72 hours 8 hours 9 T A B L E 2 - 3 . Relationship Between Setup T i m e and L o t S i z e — I I I siderable increase in productive power and reduction in needed manhours. Indeed, we might well imagine that this is the principal reason for favoring large-lot production on the shop floor. With traditional setup procedures, large-lot production seems the easiest and most effective way to minimize the undesirable effects of setup operations.
Inventory serves as a cushion, alleviating problems when defects show up or machinery breaks down. e Inventories can be used to fill rush orders. Setup Operations in the Past 17 Disadvantages • Capital turnover rates fall, increasing interest burdens. 9 Inventory itself does not produce added value, so the tremendous physical space it occupies is entirely wasted. • Inventory storage necessitates the installation of racks, pallets, and so forth, all of which increase costs. When inventories grow too large, special rack rooms or the like are installed and automated stock entry and retrieval becomes possible.
A Revolution in Manufacturing: The SMED System by Shigeo Shingo, Andrew P. Dillon