SMED principles applied to Formula 1 racing MGMT 6650 8 August 2013

2013 Malaysian Grand Prix pit-stop1 http://www.youtube.com/watch?v=iAHn6W1S1DU

What is SMED? Single-Minute Exchange of Die is one of the many lean production methods for reducing waste in a manufacturing process. It provides a rapid and efficient way of converting a manufacturing process from running the current product to running the next product.2

SMED value to business3 Economic Order Quantity Historically maximize production count to keep unit overhead cost low. High production counts create inefficiencies in other areas. SMED allows smaller production runs while retaining low unit cost. SMED supports just-in-time inventory.

Toyota background4 Shigeo Shingo - Toyota Production System, SMED Changing multi-ton precision dies on vehicle body transfer-stamping machines took anywhere from 12 to 36 hours to complete. By applying SMED Principles Toyota reduced changeover time to less than 10 minutes. Creating an EOQ of less than 1 car.

SMED 8 techniques for consideration5 Separate internal from external operations Convert internal items to external items Standardize the function, not the shape Eliminate fasteners or use functional clamps Use intermediate jigs Adopt parallel operations Eliminate adjustments Use mechanization

SMED 7 Reduction steps6 Observation (A) Separation (B) Conversion (C) Simplification on internal (D) focus on fixings Standardization of external activities (D) similar scale to internal Documentation Repetition

Key observations for improvement7 shortages, mistakes, inadequate verification of equipment causing delays and can be avoided by check tables, especially visual ones, and setup on an intermediary jig inadequate or incomplete repairs to equipment causing rework and delays optimization for least work as opposed to least delay unheated molds which require several wasted 'tests' before operating temperature to work using slow precise adjustment equipment for the large coarse part of adjustment lack of visual lines or benchmarks for part placement on the equipment forcing a changeover between different raw materials when a continuous feed, or near equivalent, is possible lack of functional standardization, that is standardization of only the parts necessary for setup e.g. all bolts use same size spanner, die grip points are in the same place on all dies significant operator movement around the equipment during setup more attachment points than actually required for the forces to be constrained attachment points that take more than one turn to fasten any adjustments after initial setup any use of experts during setup any adjustments of assisting tools such as guides or switches

SMED Techniques in action Separate internal from external operations Tools, tires, crew ready to go Convert internal items to external items Captive wheel-nut Standardize the function, not the shape Each crew has specialized task Eliminate fasteners or Use functional clamps Single wheel-nut Minimal threads Use intermediate jigs Alignment tape with position marks Adopt parallel operations 4 teams – 4 tires, other activities Eliminate adjustments Pre-calibrated air guns Use Mechanization Air guns with backup Jacks

2011 Monaco Grand Prix8 http://www.youtube.com/watch?v=RHUTYpIpBg8

Timing: 00:00:02.05 Art of Pit stop9 By Infiniti Red Bull Racing http://www.youtube.com/watch?v=lfAIvXzRXPc Timing: 00:00:02.05

Record Breaking Pit-stop team

Q & A

Appendix

2012 Championship prize

Sources 1 Anonymous, “F1 2013 – Pit Stop Record at Malaysian GP by Red Bull and Webber,” AutostradaTV http://www.youtube.com/watch?v=iAHn6W1S1DU 2 Anonymous, “Single-Minute Exchange of Die” http://en.wikipedia.org/wiki/Single-Minute_Exchange_of_Die 3 Ibid. 4 5 6 7 8 Max Halliwell, “Red Bull Double Pit Stop Monaco 2011 – Unique Footage – Webber not amused…” http://www.youtube.com/watch?v=RHUTYpIpBg8 9 Anonymous, “Art of Pit Stop,” Infiniti Red Bull Racing http://www.youtube.com/watch?v=lfAIvXzRXPc 10 Anonymous, “The Shingo Prize” http://www.shingoprize.org/the-shingo-prize.html