SMED Techniques & Cart Tuggers for More Efficient Mold Changeovers

Mold changeovers cost money – so every second counts. Driving leaders across molding and manufacturing to reduce changeovers and increase efficiency.  

Almost every shop across the world has goals and targets to reduce mold changeover times. But how do you achieve quicker changeovers?   

Understanding SMED  

SMED stands for Single-Minute Exchange of Die, and in this context, it’s a systematic approach to reduce the time associated with switching from one mold or die configuration to another. The term ‘die’ refers to specialized manufacturing tools, which need to be re-configured for any changes in production. 

The primary goal of SMED is to minimize the time it takes to switch from producing one product to another. It’s important to note that the "Single-Minute" doesn't mean changeovers will take one minute, but instead emphasizes the goal of achieving rapid changeovers. The SMED concept is designed to eliminate waste and facilitate quick changeovers to maximize efficiency as part of lean manufacturing principles.  

SMED was pioneered by Shigeo Shingo, a Japanese industrial engineer, who was able to reduce the changeover times in the companies he worked with by an average of 94% by applying SMED techniques.   

4 Tips to Achieve SMED Quicker Changeover Times 

1. Identification of Setup Elements: The first step is to identify elements and tasks involved in mold changeovers. This can include tasks like removing the existing mold, adjusting mold settings, and ensuring machines are calibrated correctly. 
   
2. Assess Internal and External Setup: Internal tasks are those that must be performed when a molding machine is stopped, like for example physically changing the mold. External tasks are those that can be done while the machine is running, such as preparing the new mold, checking tools, or arranging materials.  
    
   As part of SMED, you should focus on streamlining internal setup tasks that cannot be externalized. This could include optimizing the process for removing and installing molds, ensuring proper alignment, and reducing the need for manual adjustments. Standardizing procedures and documenting best practices can also help ensure continuity. 
3. Continuous Improvement: Continuously monitor and measure setup times for different molds. Analyze the data and look for opportunities to further optimize and improve the changeover process. 
4. Mold Transfer Methods: One of the biggest contributors to slow, inefficient changeovers is mold movement within the factory. Large, heavy molds are typically moved using a combination of overhead cranes and forklift trucks – leading to excess downtime. Die carts and handling aids like cart tuggers can be used to deliver a more efficient, flexible solution.  

Mold Movement – The Hidden Cost  

While many molding shops focus on optimizing and improving tasks within the changeover process such as setup and configuration – many businesses still overlook the hidden impacts of how molds are moved during changeovers. 

Forklift trucks are typically used to move molds from one area or building to another, often navigating through congested spaces. While overhead cranes are used to lift molds during the changeover process. Lifting molds at some stage of the process is often unavoidable, but using a combination of forklift trucks and overhead cranes to move and transfer molds from different areas of a facility results in inefficient and slow changeovers.  

During the changeover process, employees must wait for a licensed forklift driver to become available, often resulting in downtime – contributing to slower changeover times.   

With SMED techniques aligning with lean manufacturing methodology, the core objective should be to identify waste and work to reduce or eliminate it.  

Using More Efficient Mold Transfer Methods  

Die Carts, Mold Carts & Mold Tool Movers 

One way to make changeovers more flexible and efficient is by making molds more mobile.  

A range of die change carts and mold carts can be used to make it easier to move molds throughout facilities or during changeovers.  Solutions can range from complex handling stations to simpler industrial carts, but they all share the same feature – they’re moveable.  

Combining a die cart with handling equipment such as cart tuggers amplifies these benefits by allowing a single operator to safely and efficiently move heavy mold tools. Delivering maximum flexibility, cart tuggers tugs can be used to move mold carts and mold tools from building to building or throughout a facility, reducing changeover times and safely navigating through congested molding shops.  

Mold Tool Movers in Action:

The Benefits of Cart Tuggers and Die Carts  

Reduced Downtime: By minimizing changeover times, cart tuggers and die carts help to reduce the amount of time a machine or production line is not producing products – increasing overall production efficiency. 

Increased Flexibility: Faster changeovers allow manufacturers to be more responsive and flexible. Using cart tuggers and mold carts allows manufacturers to move molds and dies from different buildings, providing greater flexibility than fixed systems such as overhead crane systems.  

Lower Costs: Reduced downtime, quicker changeovers and increased efficiency lead to cost savings by reducing waste and maximizing production time.  

Explore Mold Cart Tuggers

Our battery-powered cart tuggers are the ideal solution for moving heavy mold tools and die tooling. Enjoy complete control and quicker changeovers with options ranging from pedestrian operated to remote control solutions. 

MasterTug

Up to 44,000 lbs.

Discover a safer, more efficient way of moving heavy molds weighing up to 44,000 lbs. Push, pull and steer with confidence!

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PowerSteered

Up to 66,000 lbs.

Moving molds has never been easier with our remote control solutions. Compact, powerful machines to move up to 66,000 lbs.

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AGV

Up to 66,000 lbs.

Automate your mold changeovers with Automated Guided Vehicles for maximum efficiency.

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Who Uses our Mold Tool Movers? 

We work with a diverse range of customers to unlock greater efficiency and more flexible mold and tool movement. Whether it’s moving injection mold tools, die casting tools, or press tools our customers across manufacturing and the automotive supply chain rely on us to help reduce changeovers and maximise efficiency.  

Applying SMED Techniques 

By applying SMED principles and mold tool movers to handle injection molds and mold tools, manufacturers can reduce downtime between changeovers, improve machine utilization, enhance overall efficiency, and respond more quickly to changing production requirements. This ultimately leads to cost savings, enabling production to be increased and eliminating bottlenecks in the process.  

Whether you want to reduce mold changeover times, ensure high performance or optimize non-value-adding tasks, SMED techniques and applying effective mold tool movers increases efficiency and flexibility.