Triathlon Transitions and Single Minute Exchange of Die

I maintain a popular triathlon blog here and have often thought just how similar the objectives are during the transitions (between the swim and bike, then the bike and run) and when conducting a SMED activity.

What is a transition area?

Transition areas are positioned both between the swim and bike segments (T1), and the bike and run segments (T2), and are often just one checkpoint, especially in shorter courses. These areas are used to store bicycles, performance apparel, and any other accessories essential for preparing and gearing for the next stage of the race. The times (T1 and T2) are included in the overall time of the race. So speed during transition- removing the wetsuit, putting on the helmet, putting on the running shoes – is essential

These are examples of how you should set-up your transition area:

This is how not to transition:

Here is a reasonable summary of some of the things you try to do during transition:

Practice your plan – Have a plan of exactly what you are going to do and practice it over and over again until you are fast with no mistakes. Practice it physically several times over in training and then rehearse it mentally several times on race morning. By the time you are in transition in during race you should be moving on autopilot. Never try something new on race day.

Be a minimalist – The fewer tasks you have to do in the transition area, the faster you will go. Skip the socks and get rid of anything you don’t absolutely need. Clutter will slow you down.

Bike shoes in the pedals – Coasting down the course at 15 miles per hour while you put your feet in your shoes will move you far ahead of your buddy sitting on his butt in T1 doing the same task. Set your bike up in the transition area with your shoes attached to the pedals and rubber bands looped between the heels and frame holding them horizontal. On leaving T1, pedal with your feet on top of your shoes. Once you are cruising at speed, coast and slip your feet into your shoes. Keep your eyes ahead on the road, not down on your feet. On the return, slip your feet out of your shoes before you reach T2. Learn this skill first on an indoor trainer before taking it out on the open road.

Run with your bike – The distance from rack to mount line can be considerable at large triathlons. By running safely and quickly with your bike, it is easy to fly over this distance. Run upright with good form on the left side of your bike holding your seat with your right hand. Left arm swings by your side. Hold the bike upright to go straight and lean it to the side to turn. Practice in an empty parking lot.

Speed over the mount / dismount line – Learn a cyclocross mount / dismount to cruise over this line without losing any momentum. In the race you will be doing this in bare feet but initially learn and practice this skill wearing running shoes.

Attach your stuff to your bike – Handling small items sucks up time. Everything you need on the bike course should be attached to your bike. Tape gels to the frame, water bottles should already be on board, sunglasses looped to a cable, spare tube in a seat pack and CO2 cartridge taped to the seat post.

One outfit for all occasions - Start the swim with your full bike/run outfit under your wetsuit. A one piece tri-suit is ideal. Any clothing changes will add lots of time.

Navigation - Have you ever come out of a different mall door at Christmas time and had trouble finding your car? You can have a similar experience in a large transition area. Note where your rack spot is and how to find in from the swim exit and bike entrance. From your rack, know where the bike and run exits are and the quickest route to them.

Speed laces and baby powder – Tying your running shoe laces in a bow takes time. Eliminate this step using lace locks or speed laces. To help your feet slide smoothly into your running shoes, prime them with a sprinkling of baby powder.

Grab and go – In T2, grab what you need and go. Put on your hat and fuel belt while you are running. It is always faster to complete your tasks moving down the course rather than standing in front of your rack.

And here are even more.

SMED

Shigeo Shingo recognises eight techniques that should be considered in implementing SMED.

1. Separate internal from external setup operations
2. Convert internal to external setup
3. Standardize function, not shape
4. Use functional clamps or eliminate fasteners altogether
5. Use intermediate jigs
6. Adopt parallel operations (see image below)
7. Eliminate adjustments
8. Mechanization

NB External setup can be done without the line being stopped whereas internal needs the line to be stopped.

He suggests that SMED improvement should pass through four conceptual stages:

• A. ensure that external setup actions are performed while the machine is still running
• B. separate external and internal setup actions, ensure that the parts all function and implement efficient ways of transporting the die and other parts
• C. convert internal setup actions to external
• D. improve all setup actions.

Formal method

There are seven basic steps to reducing changeover using the SMED system:

1. OBSERVE the current methodology
2. Separate the INTERNAL and EXTERNAL activities. Internal activities are those that can only be performed when the process is stopped, while External activities can be done while the last batch is being produced, or once the next batch has started. For example, go and get the required tools for the job BEFORE the machine stops.
3. Convert (where possible) Internal activities into External ones (pre-heating of tools is a good example of this).
4. Streamline the remaining internal activities, by simplifying them. Focus on fixings – Shigeo Shingo rightly observed that it’s only the last turn of a bolt that tightens it – the rest is just movement.
5. Streamline the External activities, so that they are of a similar scale to the Internal ones.
6. Document the new procedure, and actions that are yet to be completed.
7. Do it all again: For each iteration of the above process, a 45% improvement in set-up times should be expected, so it may take several iterations to cross the ten minute line.

The SMED concept is credited to Shigeo Shingo, one of the main contributors to the consolidation of the Toyota Production System, along with Taiichi Ohno.

Key elements to observe

Look for:

1. shortages, mistakes, inadequate verification of equipment causing delays and can be avoided by check tables, especially visual ones, and setup on an intermediary jig
2. inadequate or incomplete repairs to equipment causing rework and delays
3. optimization for least work as opposed to least delay
4. unheated molds which require several wasted ‘tests’ before they will be at the temperature to work
5. using slow precise adjustment equipment for the large coarse part of adjustment
6. lack of visual lines or benchmarks for part placement on the equipment
7. forcing a changeover between different raw materials when a continuous feed, or near equivalent, is possible
8. 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
9. much operator movement around the equipment during setup
10. more attachment points than actually required for the forces to be constrained
11. attachment points that take more than one turn to fasten
12. any adjustments after initial setup
13. any use of experts during setup
14. any adjustments of assisting tools such as guides or switches

Can you see the similarities? Leave a comment below.

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Comments

By robthompson on November 16th, 2009 at 7:57 am

Just published: Triathlon Transitions and Single Minute Exchange of Die: I maintain a popular triathlon blog here a… http://bit.ly/384AGa

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