Set-up reduction in an interconnection axle manufacturing cell using SMED

Abstract

This document is about how to reduce set-up time using Single-Minute Exchange of Die (SMED) on an actual production process of interconnection axles, starting with a production and indicators analysis, followed by time studies, and then the rolling-out of all the SMED stages. The first activity carried out was observation, second assessment, and followed by implementation leading to standardization and the generation of standard manufacturing documents. At this point, training was carried out thereby enabling the validation and assessment of the versatility matrix. Finally, the productivity of the manufacturing cell was evaluated by looking at the new Overall Equipment Effectiveness (OEE) indicator to demonstrate the effectiveness of SMED in reducing start-up times and the fine-tuning of machinery.

Improving Overall Equipment Effectiveness (OEE) of Extrusion Machine Using Lean Manufacturing Approach

“…Before going through this stage, an evaluation of the transportation equipment used to move the die is required to investigate the possibilities of reducing the needed time to move spare parts and other components before embarking on the actual setup steps. Setup time reduction usually provides many benefits such as reduction of stock, work in progress, batch size, and movements, as well as improvement in quality and production flexibility [30]. Lastly, Stage 3 of the SMED methodology is about rationalizing the internal and external setup for better replacement and time reduction solutions.…”

Implementasi Metode Single Minute Exchange Of Die Untuk Mengurangi Waktu Persiapan dan Penyesuaian Mold di Industri Polimer

“…Toyota telah mendefinisikan beberapa jenis aktivitas non-nilai tambah utama dalam proses manufaktur yang umumnya dikenal sebagai tujuh pemborosan atau TIMWOOD (Liker, 2004)  Muda = kapasitas lebih dari beban kerja (pemborosan nyata)  Mura = kapasitas yang berayun di sekitar target tetap (pemborosan di sini adalah yang tidak stabil)  Muri = beban kerja lebih dari kapasitas (pekerja dan mesin terlalu sibuk) SMED telah berhasil diterapkan di banyak kasus industri. Beberapa kasus diantaranya adalah Arvianto dan Arista mengusulkan penerapannya untuk perbaikan operation point sheet pada mesin feeder Aida 1100 (Arvianto & Arista, 2012), penghematan hingga 30% per tahun di perusahaan pengolahan kaca lembaran yang memproduksi ratusan jenis produk (Filla, 2016), proses produksi as roda interkoneksi (Morales Méndez & Silva Rodríguez, 2016), perbaikan desain yang sesuai dari komponen penting yaitu. perlengkapan penjepit dan tie-rod (Desai & Rawani, 2017), meningkatkan kinerja mesin di industri makanan (Lozano, Saenz-Díez, Martínez, Jiménez, & Blanco, 2017), pengurangan set-up pada mesin cetak injeksi (Amrina, Junaedi, & Prasetyo, 2018), dan praktik di pabrik garmen siap pakai di Bangladesh (Hossain, Hamja, & Rabbi, 2018).…”

SMED enhanced with 5-Whys Analysis to improve set-upreduction programs: the SWAN approach

“…This approach consists of a top-down functional analysis of machines, which helps practitioners identifying all those items impacting on the changeover process, and of a proper identification of intervention strategies also considering the novel concept of 'duplication strategy'. An interesting recent study conducted by Morales Méndez and Silva Rodríguez [18] analyses the problem of set-up reduction within an interconnection axle manufacturing cell by means of SMED. The general SMED framework is enriched with two more stages concerning, respectively, with the validation of the standard manufacturing documents previously generated and with the training of personnel involved.…”