Quick changeover design: a new Lean methodology to support the design of machines in terms of rapid changeover capability

Abstract

PurposeThis paper presents Quick Changeover Design (QCD), which is a structured methodological approach for Original Equipment Manufacturers to drive and support the design of machines in terms of rapid changeover capability.Design/methodology/approachTo improve the performance in terms of set up time, QCD addresses machine design from a single-minute digit exchange of die (SMED). Although conceived to aid the design of completely new machines, QCD can be adapted to support for simple design upgrades on pre-existing machines. The QCD is structured in three consecutive steps, each supported by specific tools and analysis forms to facilitate and better structure the designers' activities.FindingsQCD helps equipment manufacturers to understand the current and future needs of the manufacturers' customers to: (1) anticipate the requirements for new and different set-up process; (2) prioritize the possible technical solutions; (3) build machines and equipment that are easy and fast to set-up under variable contexts. When applied to a production system consisting of machines subject to frequent or time-consuming set-up processes, QCD enhances both responsiveness to external market demands and internal control of factory operations.Originality/valueThe QCD approach is a support system for the development of completely new machines and is also particularly effective in upgrading existing ones. QCD's practical application is demonstrated using a case study concerning a vertical spindle machine.

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

“…Various papers are focused on implementing conventional SMED to reduce setup time (Amrani and Ducq, 2020; Bevilacqua et al. , 2015; Braglia et al. , 2023; Ekincioğlu and Boran, 2018; McIntosh et al.…”

“…McIntosh et al (2000) investigate the role of design change in the early stages of improvement programs in reducing the duration of setup tasks or eliminating them. Mukhopadhyay and Shanker (2005) Braglia et al (2023) propose a quick changeover design to reduce setup time during the design phase which consists of four steps including identifying the type of machinery, its function and the relevant product for processing in first step, analyzing how to design the machine to achieve short setup time and easy execution of setup operations in second step, focusing on technical interventions at the project level in third step and considering the best construction solutions to minimize the time of a specific setup activity in fourth step.…”

“…performing online setting. Various papers are focused on implementing conventional SMED to reduce setup time (Amrani and Ducq, 2020;Bevilacqua et al, 2015;Braglia et al, 2023;Ekincio glu and Boran, 2018;McIntosh et al, 2000). Since the desired product quality must also be met in conventional SMED implementation, the literature elaborates application strategies such as knowledge management, organizational design (Stapelbroek et al, 2022) and standardization (Junior et al, 2022) which offer significant opportunities for reducing product losses and accomplishing the intended product quality during setup operations.…”