Reducing Model Changeover Times in the Metal Packaging Printing Process: A Case Study

Abstract

The objective of this research is to decrease the duration of model changeover times in the metal package printing process. The study involved the collection of data on the changeover times of the LP7 offset printer model, followed by the utilization of flow process charts to examine four different activities: Feeder, Printer, Coater, and Stacker. It was discovered that certain procedures experienced delays and exhibited prolonged durations. Hence, this study proposed guidelines for improvement aimed at minimizing the duration required for model alteration through the application of the Single Minute Exchange of Die (SMED) principle, achieved by transitioning internal tasks to external tasks. The application of the ECRS method involved the creation of an additional equipment to scoop ink, the use of ink duct foils to cover an ink plate, the rearrangement of work sequences, and the set of pallet shelves. The results indicated that there was a decrease in changeover times in the Printer activity, from 221.26 minutes to 167.26 minutes, resulting in a reduction of 24.41%. Similarly, in the Coater activity, the changeover times decreased from 79.45 minutes to 49.45 minutes, representing a decrease of 37.76%. Additionally, in the Stacker activity, the changeover times decreased from 55 minutes to 30 minutes, representing a reduction of 45.45% compared to the previous duration.