Last updated on Apr 23, 2024

What are the benefits and drawbacks of using external and internal setup methods in SMED and TPM?

If you want to improve your productivity and quality, you need to reduce the time and cost of changing over your machines and equipment. This is where SMED and TPM come in. SMED stands for Single-Minute Exchange of Die, a technique that aims to minimize the setup time to less than 10 minutes. TPM stands for Total Productive Maintenance, a system that involves everyone in maintaining and improving the performance of the machines and equipment. Both SMED and TPM use external and internal setup methods, but what are the benefits and drawbacks of each? Let's find out.

1 External setup

External setup refers to the activities that can be done before or after the machine is stopped, such as preparing tools, materials, and instructions. The benefits of external setup are that it reduces the downtime of the machine, increases the availability of the machine, and allows for more flexibility and responsiveness to customer demand. The drawbacks of external setup are that it may require more space, resources, and coordination, and that it may increase the risk of errors or accidents if not done properly.

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Ravi Vaidiswaran

Consulting Services
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Here work place design can play an efficient role. Keep all tools as required in proper sequence an order for the setup activities.

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2 Internal setup

Internal setup refers to the activities that can only be done when the machine is stopped, such as adjusting, clamping, or testing. The benefits of internal setup are that it ensures the quality and accuracy of the machine, and that it provides an opportunity to inspect and clean the machine. The drawbacks of internal setup are that it consumes valuable production time, reduces the output of the machine, and may require special skills or tools.

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3 How to use both methods

To optimize the setup process, you need to use both external and internal setup methods in a balanced and effective way. The first step is to identify and separate the external and internal setup activities. The second step is to convert as many internal setup activities as possible into external ones, by using standardized parts, fixtures, or settings. The third step is to simplify and streamline the remaining internal setup activities, by using quick-release mechanisms, guides, or indicators.

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4 How SMED and TPM support each other

SMED and TPM are not isolated techniques, but complementary ones. By applying SMED, you can reduce the setup time and increase the machine availability, which are key indicators of TPM. By applying TPM, you can improve the machine condition and performance, which are essential for SMED. Moreover, both SMED and TPM require the involvement and empowerment of the operators, who are the closest to the machines and can identify and solve problems faster and better.

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5 How to implement SMED and TPM

Implementing SMED and TPM is not a one-time project, but a continuous improvement process. You need to follow a systematic approach that includes the following steps: plan, do, check, and act. Plan your goals and methods, based on data and analysis. Do the actions, based on the best practices and standards. Check the results, based on the measurements and feedback. Act on the improvements, based on the learning and adjustments.

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6 How to overcome the challenges

Implementing SMED and TPM is not without challenges, but they can be overcome with the right mindset and actions. Some of the common challenges are: resistance to change, lack of skills or resources, poor communication or coordination, and insufficient support or recognition. To overcome these challenges, you need to: create a culture of teamwork and trust, provide training and coaching, establish clear roles and responsibilities, and reward and celebrate the achievements.

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