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

2. 2013 Malaysian Grand Prix pit-stop1

3. 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

4. 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.

5. 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.

6. 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

7. 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

8. 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

9. 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

10. 2011 Monaco Grand Prix8

11. Timing: 00:00:02.05 Art of Pit stop9 By Infiniti Red Bull Racing
Timing: 00:00:02.05

12. Record Breaking Pit-stop team

14. Q & A

15. Appendix

16. 2012 Championship prize

17. Sources 1
Anonymous, “F – Pit Stop Record at Malaysian GP by Red Bull and Webber,” AutostradaTV 2
Anonymous, “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…” 9
Anonymous, “Art of Pit Stop,” Infiniti Red Bull Racing 10
Anonymous, “The Shingo Prize”