SMED for quick changeover in manufacturing industry – a case study

Abstract

Purpose The purpose of this paper is to uncover the significance of SMED in manufacturing environments. Design/methodology/approach The paper gives setup instructions and guidelines to prepare the standardized setup procedure without ignoring actual constraints in production environment. It uses a case study in a small-scale manufacturing unit of northern India to generate an integrated setup reduction approach, utilizing Single Minute Exchange of Die (SMED)-based industrial engineering tools to achieve faster setups. It describes the feasibility of quick changeovers in small enterprises based on an “SMED” approach. Finally, the paper carries out empirical analysis of the financial/non-financial benefits incurred from setup reductions. Findings Setup activities are a vital part of the production lead time of any product and so affect overall product cost. Industrial engineering techniques have been used to analyze the existing procedure of setups. A SMED approach can help eliminate unwanted activities, externalize the internal activities, if possible, and reduce them by simplification or standardization. Originality/value The paper demonstrates the practical application of SMED showing how it can bring real breakthroughs in reducing setup time in small-scale manufacturing.

The 4Rs supply chain resilience framework: A capability perspective

“…Production changeover entails adapting to the new situation by switching production to different products. Singh et al (2018) emphasize that manufacturing firms respond quickly to new demand. The changeover's speed of response depends on the following capabilities: Retooling, repurposing, reconfiguration and recalibrating.…”

Optimization model to increase the efficiency of the flexible packaging production process applying the Johnson Method, SMED and TPM in a SME in the Plastics Sector

“…The SMED tool provides instructions and guidelines for standardizing configuration activities, considering the real limitations in the production environment [17]. Several studies of the industrial sector adopt production models that integrate the conventional SMED tool with other techniques such as the Method of Evaluation of Muscle Fatigue with the Taguchi Method, and the Statistical Analysis with Visual Management, to achieve a 62.5% and 30% reduction in machine setup time, respectively [18] [19].…”

Optimising Changeover through Lean-Manufacturing Principles: A Case Study in a Food Factory

“…Activities are classified as internal when production has stopped for changeover and as external when production is still running. SMED is widely accepted and adopted in the manufacturing industry [7][8][9].…”

“…A small manufacturing facility in Northern India implemented SMED and reported a reduction of time for changeovers of 42.27 min by preheating the die heads, using a pneumatic spanner, and standardising the cut off die length [9]. Another example of SMED implementation occurred in a stamping production line at an automobile company in Switzerland.…”