Single Minute Exchange Of Die Research Articles

METHODOLOGY TO MAXIMIZE ZERO LOSSES THROUGH SMED IN FOOD INDUSTRY

METHODOLOGY TO MAXIMIZE ZERO LOSSES THROUGH SMED IN FOOD INDUSTRY

Implementasi Metode Single Minute Exchange of Dies Untuk Optimasi Setting Time Mesin Flexo B1 Grup C Pada Carton Box Departement PT. A

PT. A is a company engaged in the production and sale of paper, cardboard boxes, and other similar products in Indonesia. The products it offers include paper, tissue, packaging, and other products. The Carton Box Department, from the results of observations made, the average actual setting time on the Flexo B1 Group C machine is 47 minutes/order, this is one of the weaknesses that causes a 32-minute gap from the target set by the company which is 15 minutes/order. The research objectives are to analyze, improve, and obtain improved setting time results on the Flexo B1 Group C machine and the production process time carried out. The SMED (Single Minute Exchange of Dies) method is one approach that can be pursued in improving setting time. The influence of the SMED (Single Minute Exchange of Dies) method in optimizing the setting time of the Flexo B1 Group C machine results in a decrease in setting time with a setup duration of 49.11 minutes, normal time of 59 minutes, and standard time 66 minutes to a setup duration 25.36 minutes, normal time 27 minutes and standard time 34 minutes and the percentage obtained is 51.8%. Keywords: Lean Manufacturing, Productivity, Single Minute Exchange of Dies

Reducing Dandory Exchange Process Time on 1800 Ton Injection Molding Machine Using the Single Minute Exchange of Dies (Smed) Method at PT Takagi Sari Multi Utama

Takagi Sari Multi Utama is an automotive company engaged in injection molding, producing automotive products such as motor vehicle parts, car interiors, and exteriors. One of the main influences of the prolonged dandory process is the distance between the mold parking area and the machine, resulting in a total process time of 48.95 minutes, while the company's standard is set at 40 minutes. Minimizing the time can cause the dandory process of mold change using the Single Minute Exchange of Dies (SMED) method by converting the time of internal setup activities into external setup activities. The improvement results using the Single Minute Exchange of Dies (SMED) method reduced the time to 27.67 minutes or equivalent to 1,660.13 seconds. The reduction in dandory mold change process time on the 1800T injection molding machine is 21.29 minutes or equivalent to 1,277.16 seconds, with a percentage decrease of 44%

Network Meta-Analysis for Determining the Best Lean Tools Synergy to Improve Productivity by Reducing Rework in Garment Factories

The textile industry plays an important role in the global economy; however, it faces persistent challenges related to reducing rework for improving productivity. The purpose of this study is to summarize some scientific researches about production delay caused by rework in a clothing and accessory industry. It provides a general overview of the current state of knowledge concerning the interdependence between reduced productivity and rework rate. The research process is based on the Functional Analysis System Technique. It facilitates a systematic examination of sequential and logical steps necessary to achieve objective and attain outcomes. Functional Analysis System Techniques not only provides a structured methodology but also aids in identifying the successive functions crucial for attaining desired outcomes. The initial phase involves conducting a comprehensive systematic literature review focused on productivity issues stemming from rework within the textile industry. The first phase, related to the Seiri of the 5S methodology, involves conducting a comprehensive systematic literature review focused on productivity issues stemming from rework within the textile industry. Subsequently, the filling of a literature review synthesis matrix using Excel is conducted which represents Seiton. Next, focusing specifically on the Lean tools employed utilized and the corresponding productivity improvements, data are extracted. This corresponds to Seiso step. Following this, a Network Meta-Analysis is applied, representing the Seiketsu. Finally, the identification of the most effective Lean tools combination to reduce rework is undertaken, corresponding to Shitsuke. As results, the Ishikawa Diagram appears to have obtained the best ranking position according to the rankogram. Ishikawa Diagram is often associated with other tools to multiply its performance. The study's findings highlight that the Ishikawa, Pareto, Single-Minute Exchange of Die and Work Study combination emerges as the most effective approach for minimizing rework and enhancing productivity, as indicated by the League Table. This network meta-analysis provides a comprehensive overview of the Lean tools synergy effectiveness in rework reduction and productivity improvement strategies in textile industries. While powerful, Network Meta-Analysis has limitations including reliance on indirect comparisons from studies that may not directly compare all treatments, inheriting biases and complexities, which can pose challenges in assessing result certainty.

SMED 4.0: a development of single minute exchange of die in the era of Industry 4.0 technologies to improve sustainability

PurposeThis paper recommends a method entitled “SMED 4.0” as a development of conventional single minute exchange of die (SMED) to avoid defect occurrence during production and improve sustainability, besides reducing setup time.Design/methodology/approachThe method builds upon an extensive literature review and in-depth explorative research in SMED and zero defect manufacturing (ZDM). SMED 4.0 incorporates an evolutionary stage that employs predict-prevent strategies using Industry 4.0 technologies including the Internet of Things (IoT) and machine learning (ML) algorithms.FindingsIt presents the applicability of the proposed approach in (1) identifying the triple bottom line (TBL) criteria, which are affected by defects; (2) predicting the time of defect occurrence if any; (3) preventing defective products by performing online setting on machines during production as needed; (4) maintaining the desired quality of the product during the production and (5) improving TBL sustainability in manufacturing processes.Originality/valueThe extended view of SMED 4.0 in this research, as well as its analytical approach, helps practitioners develop their SMED approaches in a more holistic way. The practical application of SMED 4.0 is illustrated by implementing it in a real-life manufacturing case.

Improving changeover techniques in apparel manufacturing through single minute exchange of die: implications for benchmarking

PurposeBangladesh's ready-made garment (RMG) industry plays a vital role in the economic growth of this country. As the global trend in the fashion market has introduced a high-mix, low-volume ordering style, manufacturers are facing an increased number of changeovers in their production systems. However, most of the Bangladeshi RMG manufacturers are not yet ready to respond to such small orders and to improve the flexibility of their production systems. Consequently, the industry is falling behind in global market competition. Thus, this study aims to advance the current performance of RMG manufacturing operations to respond to the fast-fashion industry's challenges effectively using quick changeover.Design/methodology/approachIn this study, a Single-Minute Exchange of Dies (SMED) is applied to attain quick changeover following the best practices of lean manufacturing.FindingsThis study examined the performance of the SMED technique to reduce changeover time in two case organisations. The changeover time was reduced by 70.76% from 434.56 min to 127.08 min and 42.12% from 2,664 min to 1,542 min for the case organisations, respectively. The results of this study show that companies require improved changeover times to address the demand for high-mix, low-volume orders.Originality/valueThis study will certainly guide practitioners of the RMG industry to adopt SMED to reduce changeover time to meet small batch production.

Implementasi Metode Single Minute Exchange of Dies di Bagian Packing Dalam Upaya Meminimasi Pemborosan (Waste) Dan Peningkatan Produktivitas (Studi Kasus PT. SF)

PT. SF is a company engaged in the pharmaceutical industry. This company has several problems faced, one of the problems that often occurs is the high time in the machine setup process , so that the fulfillment of production targets is disrupted. The number of types of products makes the number of model change processes which of course have different types, so that this has an impact on the amount of production produced. Therefore, this study was conducted to minimize setup time using the single minute exchange of dies (SMED) method. The results showed that there were 5 work stations in the packing section, where of these 5 work stations the one with the highest setup time was the cartoning machine workstation with an initial setup time of 63,84 minutes. After applying the single minute exchange of dies (SMED) method, the setup process can be lowered to 46,69 minutes. So it can save set-up time by 17.15 minutes. Keywords: SMED implementation, setup time improvement, internal setup, external setup

APPLICATION OF THE SMED METHODOLOGY FOR REDUCING SETUP TIME IN THE ASSEMBLY OF ELECTRONIC COMPONENTS ON PRINTED CIRCUIT BOARDS

This work presents a case study that uses one of the tools of the management system TPM (Total Productive Maintenance) or "Total Productive Maintenance", known as SMED (Single Minute Exchange of Die) "Tool exchange in just one minute digit”, created by Shigeo Shingo. In this work, a Pareto chart and a cause-and-effect diagram were used. Its objective is to demonstrate an improvement proposal achieved by an Industry of Polo De Duas Rodas in Manaus / AM that reduced the number of hours stopped in a production line assembly of components, thus being able to respond to the increased demands of its customers. This research concludes emphasizing that with the implementation of the steps of this methodology, it was possible to achieve an expressive increase in production, with a 78% reduction in the time spent to carry out the setup of the production line.

Using the Single Minute Exchange of Die (SMED) Method to Minimize Machine Setup Time: A Case Study

PT. GTC is a company that produces automobile tubes facing problems with an increase in demand of up to 20% from the previous year. From 4 existing divisions named mixing, extruding, splicing, and curing, it was found that the extruding division was unable to meet the production targets set by the company. There are several causes, including high setup time. This research aims to reduce setup time by applying the Single Minute Exchange of Die (SMED) method to the production process in the extruding machine-1 that produces automobile tube sizes 5.50-13 and 7.00-14. Converting activities no. 2, 3, and 14 from internal activities to external activities, changing the layout of the die, core, and adjuster key storage table, dies unification, and installing a Temperature Control Unit to control steam to the extruder head can reduce setup time from 45 minutes to 22 minutes or 51% from the initial setup time. These improvements succeeded in increasing the productivity of the extruding division up to 93.9% in January 2023. Keywords: single-minute exchange of die, SMED, setup time, production achievement, unification

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

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.

Reducing dandori processing time using the single minute exchange of die method in swaging areas in automotive rubber components company

The automotive component company is engaged in the manufacture of automotive rubber components. Based on data obtained from field observations, it was found that the Dandori process on the swaging Nox machine, especially TA090 type, had the highest downtime compared to another component. Based on these problems, research uses the Single Minute Exchange of Die (SMED) method to reduce Dandori downtime in the TA090 swaging process. The SMED method was carried out in three stages: 1. identify internal and external setup, 2. Converting internal to external setup, and 3. Streamlining aspects of operation. In addition, it also used data processing tools, namely SMART, fishbone, and 5W+1H as support to solve this problem. Improvements were made by converting internal work elements into external ones and streamlining aspects of operation by improving on man, method, and machine/tools categories. The result of these improvements was a decrease in downtime of 39 minutes 48 seconds and the improvement efficiency achieved was 81.2%.

Development of a method for evaluation of internal processes in Brazilian Emergency Care Units (ECUs) through Toyota Kata and Single Minute Exchange of Die (SMED)

Development of a method for evaluation of internal processes in Brazilian Emergency Care Units (ECUs) through Toyota Kata and Single Minute Exchange of Die (SMED)

Reduction in setup time for the POLO part on the MAUSA B CNC machine

With the increasing demand for industries to enhance production at reduced costs while minimizing lead time, adopting efficient tools and techniques to optimize the manufacturing process has become crucial. The primary objective of this study was to boost productivity and simplify the entire setup process for the Polo component on a MAUSA B CNC machine by introducing the SMED (Single Minute Exchange of Die) approach, which aims to minimize machine and tool setup duration. The process in question has a lengthy manufacturing cycle, necessitating the implementation of sophisticated approaches to achieve substantial outcomes in reducing the cycle. Additionally, the process requires well-structured planning, which differs from serial processes where minor solutions can yield significant benefits in terms of cost and production cycle reduction. This article outlines the solutions and enhancements utilized in the process.

Reduksi Waktu Set up Pekerjaan Penggantian Ban Sepeda Motor dengan Metode Single Minute Exchange of Dies

Currently, almost every household in Indonesia has a motorbike, this is certainly a business opportunity. One of the most important components of a motorbike is the tire which functions to reduce vibration and protect the wheel from wear and damage. The business environment operating in the automotive sector needs to create high-quality goods or services to increase customer satisfaction. Costs in the company's productive processes must be reduced to achieve effectiveness. The object of this research is the XYZ Tire Workshop located in East Jakarta. In a day, the XYZ Ban workshop can provide up to 25 to 30 motorbike tire changes. Meanwhile, the workforce on duty is only 2 mechanics and the quantity of tools is limited. This causes delays and makes customers have to wait quite a long time before their motorbike can be worked on. The Single Minute Exchange of Dies (SMED) method which is included in lean tools is the key to reducing set-up process time. In general, SMED aims to standardize and simplify operating processes. The SMED technique is used as an element in Total Productivity Maintenance (TPM) in various studies to achieve lean manufacturing. Based on research data, the set-up time before implementing SMED was 177 seconds. After implementing the SMED method, the setup time was 126 seconds. This shows that the SMED method can reduce set-up time by 51 seconds.

Setup Time Reduction of an Automotive Parts Assembly Line Using Lean Tools and Quality Tools

The business world is becoming more competitive. Therefore, it is crucial to increase the flexibility of production by decreasing the time used in the processes of preparing the production lines for new items’ production, reducing changeover and setup times. This paper presents a case study where the main goal is to reduce the setup time of welding robots. Single Minute Exchange of Die (SMED) was implemented, using other tools such as the Spaghetti Diagram, ERCS Analysis (Eliminate, Rearrange, Combine, Simplify), Gemba Walk, Standardized Work, Flowcharts, and Pareto Diagram. The setup time decreased by 36% in the welding robots studied, decreasing the motions by 43% during the changeover process and reducing the time from the categories: “transportation”, “main”, “other”, and “waiting”. In addition to SMED implementation, this study offers an integrated study of several Lean tools and Quality tools to achieve the maximum reduction of changeover and setup times.

A Model to Reduce Machine Changeover Time and Improve Production Efficiency in an Automotive Manufacturing Organisation

One of the key postulates of the modern automotive industry is the increase in production efficiency while minimizing costs. In the opinion of experts from the automotive industry, meeting this condition may be the first stage on the way to preventing waste generation and implementing a circular economy model. The article presents a case study of issues related to the lean manufacturing methodology in terms of the impact of shortening the changeover time of the assembly line on the overall production efficiency. The presented considerations focus on the optimization of the production process using the SMED (Single Minute Exchange of Die) technique of a selected spare part. From the point of view of the Lean Manufacturing concept, the main goal of the SMED technique is to increase the flexibility of responding to changing customer needs by shortening the changeover times and faster responses to changing orders. The article describes the stages of implementing the SMED method and its impact on the increase in the OEE (Overall Equipment Efficiency) index, which allows for the percentage recognition of the degree of machine park utilization, which is one of the key factors for assessing energy efficiency. In addition, the benefits that have been achieved by using this method in terms of time and economy have been presented. The theoretical aspects related to the method used were supplemented with its practical implementation in order to improve the changeovers in a manufacturing company in the automotive industry. Based on the obtained test results, an analysis of the effectiveness of the measures taken to reduce the changeover time was carried out. The use of the SMED methodology contributed to a significant reduction in changeover time—by as much as 291.4 s. The burden on operators was significantly reduced—the total time and number of operations performed by them (both internal and external) was reduced. Operator paths have also been shortened using simple procedures such as changing the layout of the lines and modifying the changeover tool trolleys and tool locking system at the stations. The presented research may be helpful in answering the question whether the implementation of the SMED idea may be the key to effective resource management and, at a later stage, to the implementation of the circular economy model. In addition, the research results can find their practical application among both manufacturers of spare parts and the vehicles themselves, considering introducing process changes on their production lines in order to increase production efficiency and implementing the idea of industrial sustainability.

Improvement of the efficiency in the injection process in a company of the automotive sector through the implementation of the SMED (Single-Minute Exchange of Die) methodology

This work was carried out in order to reduce the excessive time in the changes of injection molds, both for aluminum and wood, each of these in their respective pilot areas that were implemented within strategic points were of great help to detect other areas of opportunity for injection in general. However, the equipment and molds used in the injection process are expensive, therefore, the use for product customization in the automotive industry forces the companies that supply inputs to the assemblers to reduce defects and downtime. The results obtained with the implementation of the present methodology generated positive numbers with respect to the time for mold change, obtaining a record change time of 15 minutes, demonstrating that if we look for the appropriate conditions and the necessary tool, we can have the minimum time in addition to obtaining also a maximum time of 3 hours and obtaining a saving of over 93 % equivalent to 255,549.37 USD

Reduction of changeover time through SMED with RACI integration in garment factories

Purpose Shorter lead time with low price and quality product demand is pivotal in the garment industry. Pressure on production lead time stresses the importance of reducing style changeover time in manufacturing factories, and this paper aims to contribute to solving the challenge by showing how the single minute exchange of die (SMED) methodology in practice can be adapted to garment factories in developing countries. Design/methodology/approach The paper investigates three cases of SMED implementation integrated with responsible, accountable, consulted, informed (RACI) matrices in garment factories in an action research approach. Both quantitative and qualitative methods are applied. Findings The study shows a reduction of 50% to 64% of changeover time with SMED implementation measured with two key indicators – throughout time and time to reach peak production. Moreover, the implementation depends on the application of the RACI matrix for the distribution of responsibility as well as integration with the basic production flow before and after the application of SMED. Practical implications The study can guide better SMED implementation in garment factories with limited investment by stressing the need to adapt to the specifics of the garment industry, secure the division of responsibility and integrate SMED in the production flow before and after the changeover. Originality/value Limited research on the application of SMED in the garment industry. This paper contributes to understanding the specific conditions for successful implementation in the garment industry in developing countries and addresses additional activities that help secure a sustainable implementation process.

A new Lean tool for efficiency evaluation in SMED projects

The ability of companies to rapidly conduct a changeover from one product to another as part of a production process is a fundamental step towards a more flexible production system that can deal with an increasingly dynamic and competitive market. Single-Minute Exchange of Die (SMED) is the best-known lean tool that aims to reduce time consumption in the changeover process. This paper presents a new lean tool called Set-up Saving Deployment (SSD), which improves set-up efficiency by classifying, analyzing, and removing set-up losses within a changeover process, and which supports decision-making for SMED implementation. SSD uses three matrices, constructed sequentially from the first (L-Matrix) to the last (ECE-Matrix), in order to assess the possible time savings that can be achieved by eliminating losses and, in addition, to forecast possible improvements resulting from implementing a SMED project. SSD also provides a new basket of tailored set-up efficiency indicators that allow the analysis team to correctly assess set-up efficiency and compare the “as is” condition with the subsequent “to be” condition from an operational perspective. The effectiveness of SSD in addressing set-up losses and predicting time savings is illustrated using an industrial case study of a resin-doming machine. Thanks to its structured step-by-step procedure, SSD significantly improves the efficiency of the changeover process.

Reduction of Manufacturing Lead Time by Value Stream Mapping of a Selected RMG Factory in Bangladesh

Bangladesh is a fast-growing economy powered by the readymade garments (RMG) industry which has promoted the country in the world through the motto ‘Made in Bangladesh’. The RMG industry has become the lifeline of the economy of Bangladesh. However, this industry faces several significant obstacles to its continued, sustainable expansion. The trading climate has become very competitive because of the phase-out of the export quota system. Additionally, with today’s rapid fashion, consumers want items with short lead times and affordable prices. Adopting the lean methodology across the board in the garment business is essential for long-term sustainability in this cutthroat context. Lean manufacturing is a philosophy to deliver the finest goods on time with minimum endeavor and less price. Lean manufacturing aims to cut lead times and remove wastes that don’t impose value on products. The purpose of this research is to identify wastes and to reduce manufacturing lead time by eliminating or reducing the excess tasks that cause higher lead time by implementing lean concepts. But implementing lean philosophy is a difficult task. During the visit to the selected RMG factory, the Short Sleeve T-shirt, one of their products, was selected for conducting this research. All the processes were observed required for the transformation of raw materials into a finished T-shirt. During the observations, the methodology of time study was applied to collect the data. Necessary information was gathered by observing the processes and interacting with the executives. Then, the current state of the value stream mapping was drawn. Wastes, responsible for a longer time, were ranked by taking the help of an 80-20 rules diagram. After this, root cause analysis was performed to find the reasons for the unwanted time consumption. Improvement strategies were introduced to reduce waste. Lean tools like Kanban to reduce WIP, Single Minute Exchange of Die to reduce changeover time, and Total Productive Maintenance to reduce machine breakdown were used to minimize the waste. Based on improvement strategies, The value stream mapping’s future state was illustrated, showing the refinement where total manufacturing lead time was reduced by 61.20%. Finally, this research has suggested some recommendations to the management of the selected RMG factory to minimize waste and increase efficiency and reduce waste in the operations. This research illustrates the usual conditions of the RMG industry of Bangladesh by presenting the current state of the value stream. The Bangladeshi clothing sector must completely embrace lean principles and embark on the direction of sustainable growth.