Abstract
Metal stamping industry has Quick Die Change (QDC) as a form of Single Minutes Exchange of Dies (SMED) as an efficient production technique where the implementation depends on operator’s activities, clamping system, accessories type and position, etc. This QDC could apply to improve the process efficiency, control of inventory and reducing the cost. This research compared the traditional metal stamping process and QDC System (QDCS) of metal stamping. This research was using Focused Group Discussion (FGD), direct observation and experiments, conducted in a private metal stamping company in wider Jakarta region of Indonesia. It was observed that the QDCS significantly reduces setup time, storage space and the cost. The setup time and cost reduced to one third of the conventional and the requirement of storage decreased by 70%. In addition, QDCS reduces the waste significantly.
Highlights
In the field of manufacturing industry especially metal stamping industry, the Single Minute Exchange of Die (SMED) founded by Shigeo Shingo during 1950’s is the most widely used [1]
2 QUICK DIE CHANGE The SMED technique invented by Shigeo Shingo may increase production capacity up to 40% by making a clear arrangement of the production activities [1]
4 ANALYSIS OF SETUP TIME EFFICIENCIES The QDC System (QDCS) is the combination of QDCD and QDCH where QDCD is very light in weight so it can be carried by hand, while conventional dies must be carried by lifting device
Summary
In the field of manufacturing industry especially metal stamping industry, the Single Minute Exchange of Die (SMED) founded by Shigeo Shingo during 1950’s is the most widely used [1]. Due to high production rate, product variability, short product’s lifecycle and inventories, the SMED technique become a popular method in metal stamping industries [2]. Later, this SMED technique developed to other field of industry outside metal stamping. Today’s trend required higher demand of product variation by the costumer This has become a big problem for metal stamping company, since metal stamping required large quantity production to reduce the overall cost. Large product variation required frequent change of tools (die set) and low scale production than usual which make company to focus on process innovation [3]. Most of the QDC techniques associated with machine and tools accessories, operator’s activities such as clearing area, clamping, setting, etc. [5], which reduces the waste and save 75% time and 50% manpower [6]
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