Single Minute Exchange of Dies: Classical Tool of Lean Manufacturing (original) (raw)
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Productivity Improvement through Single Minute Exchange of Die (SMED) Technique
To stand up in today’s highly competitive world, the manufacturers need to find a way to reduce the production time. Elimination of the wastes can improve the productivity of the company. By making use of the lean manufacturing tools the company can remain in competition and they can survive in modern world. The main objective of this project is to reduce the setup time of the Gear Hobbing Machine by 20 – 25 % through Single Minute Exchange of Die (SMED) Technique and thereby improving the productivity. The work is carried out at a gear manufacturing company. Careful observation is done while changeover or setup and maximum possible internal activities have been converted to the external activities and then some of the activities were made parallel, hence saving a considerable amount of time.
Process Improvement through Single Minute Exchange of Dies for Reduction of Changeover Time
Proceedings of the International Conference on Industrial Engineering and Operations Management
Businesses around the world strive to operational costs and waste across their supply chains to remain competitive in the growing global market. Initiatives for setup duration reduction are critical for lean manufacturing implementation despite than many organisations that initiate Single Minute Exchange of Dies (SMED) fail on implementation. The plastic injection moulding machines at an engineering firm are characterised by an ineffective process and the main problem was that the single changeover time ranged from 45 min to over 60 minutes, thereby leading to longer downtime and less production time. The scenario resulted in production capacity constraints, longer lead times and this led to loss of future business with some of the customers due to failure to meet delivery dates. The objective of this study is to identify and separate external and internal elements, establish cycle time and reduce tool changeover time for the plastic injection moulding machines. By implementing the new tailor-made SMED improvement programme of having tools ready before machine stops running, combining steps, bringing tool-holder before commencing the tool change process and establishing the production sequence to take advantage of temperatures, material type and colour, the engineering firm achieved 22% reduction in changeover time.
Implementation of Single Minute Exchange of Die in Motor Manufacturing Unit
Nowadays, industries are adopting new tools and techniques to increase productivity, operational availability and better overall efficiency of the production line. The Single Minute Exchange of Die (SMED) is one important lean tool to reduce waste and improve flexibility in manufacturing processes allowing lot size reduction and manufacturing flow improvements. SMED reduces the non-productive time by streamlining and standardizing the operations for exchange tools, using simple techniques and easy applications. However, the process doesn't give the specific actions to implement which can result in overlooking improvements. To overcome this, common statistical and industrial engineering tools can be integrated in the SMED approach to improve SMED implementation results. The applicability of the SMED technique was tested for 8 ton notching machine press changeover at the motors plant. The implementation has enabled reduction in setup time, without the need for significant investment.
International Journal of Engineering Research and Advanced Technology (IJERAT), 2022
PT X is a manufacturing company engaged in the manufacture of automotive components. This company is a joint venture between an Indonesian company and a Japanese company. The company's main products are grouped into Drive Train, Engine Related Part, and Body Related Part. As a multinational company, the company's ability to maintain efficiency is very important. Of course, to keep the market competitive and to win the competition. One of the efficiencies that must be done is to reduce unproductive time, namely time that does not produce products. This research will focus more on the timing of the model changeover. Product XZ is one of the superior products of PT. X, but from the data obtained, this production line only has an effective time of 73% of the total working hours. This is due to the high time to change the model on the work track. The time to change the model reaches 25.75 minutes. So that the maximum production capacity is 5,968 pcs / day. To solve this problem, the Single Minutes Exchange of Dies (SMED) method is used. By implementing the 7 steps of SMED and supported by problem analysis using Pareto diagrams and why-why analysis, improvement in Production time productivity is increased by 25.3%, whereas, the productivity of the production line shows improvement from 6.94 parts/minute to 8.70 parts/minute.
The Use of Lean Manufacturing Techniques – SMED Analysis to Optimization of the Production Process
Advances in Science and Technology Research Journal
Lean is a culture of real and continuous optimization. As a concept of continuous optimization in the midst of limited resources, it must be practiced continuously as a long-term organizational norm. This paper revels why changeover time reduction is important in manufacturing industries and from the various tools and techniques available within Lean manufacturing describes mainly SMED (Single Minute Exchange of Dies) for changeover time reduction and its application in Shaft manufacturing industry. This paper also describes principles, benefits, procedures and practical application of SMED. Theoretical bases are verified in a practical part that describes the analysis and design optimization of non-productive time at changeover honing machine in a selected shaft manufacturing company. The output is the structural design of universal palettes and an evaluation of productivity due to optimization of operations of time honing gear shafts. The results achieved show considerable reduction in delay arising out of machine setting time, batch-setting time and demonstration delay.
Process Improvement and Setup Time Reduction in Manufacturing Industry: A Case Study
Nowadays, due to varying customer demands and demand of shorter delivery periods of the products, there is a need for the forging industries to adopt the lean manufacturing techniques over traditional methods to increase productivity, operational availability and better overall efficiency of the production line. The present study is aimed at studying the results derived after the Single Minute Exchange of Die (SMED) implementation at ABC Company. The Study consisted of a pilot study followed by the data collection then the data was analyzed for the losses and the possible solutions for the successful implementation of SMED. During the study it was observed there were 130 setups done in a month on a forging hammer and average setup time was 160 minutes. SMED methodology and other Lean Production tools were applied to reduce the setup times observed at the beginning of the project. With the developed solutions it is possible to reduce setup times, several changeover activities can be ...
2023
The expanding manufacturing sector of plastic items is coming about because of the injection molding process and the quick advancement of existing innovation. One of the most time-consuming, non-value-added tasks in a manufacturing process is setup, or changeover. The study was conducted at a plastic product manufacturing company in Bangladesh. This study's goal was to demonstrate how changeover time reduction approaches may be used in a medium-sized production facility to cut down on total process lead time with the assistance of lean manufacturing tools. The analysis of numerous factors, including non-conformities, complaints, and delivery delays, revealed improvement prospects. In this research, three cases were considered for reducing overall changeover time: one is Reduce 7 Wastes (Case 1), the second is Improve SMED with 5S and 7 Wastes (Case 2), and the third is Total Change Over Works, which can be classified into external and internal works (Case 3). After implementing improvement measures, changeover time was reduced by 18%-33%. The most essentially decreased changeover time was 33% compared to the result for case 2, and they improved their main manufacturing line's output capacity by 10% by focusing on lean tools (5S, SMED, 7 waste). The company was able to avoid using temporary workers due to this development since it allowed employees to work longer hours during peak times. The study also explores how these techniques may be used in other major manufacturing industries that engage in mass production at several worldwide locations, in addition to a medium-sized facility.
SETUP TIME REDUCTION USING SINGLE MINUTE EXCHANGE OF DIE IN TEXTILE INDUSTRY
Nowadays to meet the production demand in textile industry, setup time reduction is a big challenge for the companies. Moreover, product customization has been increasing which negatively affects the setup time. Thus, there is need of an effective technique which can reduce the setup time. Therefore, Single Minute Exchange of Die (SMED) has been proposed in this study, it allows to optimize the changeover activity. Moreover it helps these industries to have maximum production flow. To show the practical applicability of SMED, a case study has been carried out of the changeover activity of printing rotaries in processing department of a textile industry. The results of the study showed that, 36% reduction in setup time has been achieved i-e 7 minutes 42sec were reduced per change over. It increased the production by 2.21% per day, which benefited the company to achieve higher production.
Application of SMED (Single Minutes Exchange of Die) for Production Optimization
2018
For optimization of engineering production, it is proposed to use a system of quick changeover (SMED). The introduction of this approach will enhance, in particular, the increment of the coefficient of technical use of equipment A (availability factor) by reducing non-productive time downtime. In this case, A is used as the optimization parameter. Examples of technical decisions applying SMED are presented.