Lean Manufacturing Tools – III : SMED, JIDOKA and KAIZEN

Description

INTRODUCTION

This course on Lean Manufacturing Tools – III : SMED, JIDOKA & KAIZEN is part of the Lean Manufacturing Tools Specialization series that is designed to give an introductory and intermediate level of familiarization on Lean manufacturing which is based on principles of the Toyota Production System.

SMED (Single-Minute Exchange of Dies) is a system for dramatically reducing the time it takes to complete equipment changeovers. The essence of the SMED system is to convert as many changeover steps as possible to “external” (performed while the equipment is running), and to simplify and streamline the remaining steps. The name Single-Minute Exchange of Dies comes from the goal of reducing changeover times to the “single” digits

The concept of JIDOKA originated in the early 1900s when Sakichi Toyoda, founder of the Toyota Group, invented a textile loom that stopped automatically when any thread broke. This principle became known as AUTONOMATION or automation with a human touch.

The first step of Jidoka is that of detecting an abnormality, so the machine uses simple sensors to detect a problem and then stops and highlights the problems for the operator. This enables to build in quality at each process and to separate men and machines for more efficient work.

Autonomation eliminates the need for operators to continuously watch machines and leads in turn to large productivity gains because one operator can handle several machines, often termed multi-process handling.

KAIZEN – culture of continuous improvement where all employees are actively engaged in improving the company.

Create and nurture this culture by organizing events focused on improving specific areas of the company. Continuous Improvement is a strategy where employees at all levels of a company work together proactively to achieve regular, incremental improvements to the manufacturing process. In a sense, it combines the collective talents within a company to create a powerful engine for improvement.

Kaizen works hand-in-hand with Standardized Work. Standardized Work captures the current best practices for a process, and Kaizen aims to find improvements for those processes. Note the emphasis on current; Standardized Work is living documentation (it continually evolves through Kaizen).

LEARNING OBJECTIVES

The course is designed as a very powerful pedagogic package interspersed with videos so that all related principles are captured as very important learning.

An understanding of the principles is essential for all – both in management and technical workforce.

On completion of this course, the user will have a good knowledge of

• Single Minute Exchange of Dies – SMED – related to changeover / converting a line or machine from running one product to another which permits to reduce time of manufacturing
• JIDOKA (Autonomation) – intelligently designed features of machines that can detect errors and stop autonomously
• Kaizen – culture of continuous improvement

This course is ALSO part of the is a Bundled Specialization course titled Lean Manufacturing Tools Specialization.

After this series, the participant can appreciate any course on TPS or lean manufacturing which are at intermediate or advanced levels.

ALL of our courses in this series is developed based on decades of front-line industry experience of the instructor. 

WHO SHOULD TAKE THIS COURSE

Anyone who is involved with any process, be it manufacturing or transactional. Several TPS principles can be applied in any context. It is uniformly applicable across any function. This course is equally important to any operator or management staff, , especially a new employee

You might also want to consider  to take the course on Six Sigma Specialization along with this course.

COURSE CONTENT 

• INTRODUCTION
• SINGLE-MINUTE EXCHANGE OF DIE (SMED)
  • Video : F1 Pitstop 1950 vs 2013
  • What is SMED
  • History of SMED
  • Changeover activities
  • Changeover elements
  • Advantages of SMED
  • Steps in a Changeover
  • Tips for Changeover
• JIDOKA
  • Video : Automated Loom
  • What is Jidoka
  • Autonomation – an important pillar
  • JIDOKA drives efficiency
  • Summary of JIDOKA
• KAIZEN
  • Continuous Improvement
  • Spirit of improvement
  • Video : Kaizen
  • Advantages of Kaizen
  • The Kaizen umbrella
  • 10 Commandments of Kaizen
  • Kaizen versus Innovation
  • Innovation, Kaizen and Mantenance
• REFERENCES & COURSE HANDOUTS
• FINAL QUIZ