A novel framework for single-minute exchange of die (SMED) assisted by lean tools

Pattaro, Roberto Giani; Inácio, Ricardo Henrique; Silva, Íris Bento da; Hassui, Amauri; Barbosa, Gustavo Franco

doi:10.1007/s00170-021-08534-w

Cited by 22 publications

(21 citation statements)

References 30 publications

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“…Again, Braglia et al [22] proposed an integrated approach to enhance the conventional SMED. Recently, Pattaro Junior et al [2] developed a framework based on a practical application of strategies such as improvements by ECRS (eliminate, combine, reduce, and simplify), standardized work (SW), and Overall Equipment Effectiveness (OEE).…”

Section: Single-minute Exchange Of Diementioning

confidence: 99%

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A new Lean tool for efficiency evaluation in SMED projects

Braglia¹,

Paco

MARRAZZINI³

2023

Preprint

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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.

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Section: Single-minute Exchange Of Diementioning

confidence: 99%

“…Lean manufacturing aims at maximizing the value of the product through the minimization of novalue-added activities, and dedicates particular attention to set-up time reduction to get rapid changeover of dies and equipment [2].…”

Section: Introductionmentioning

confidence: 99%

A new Lean tool for efficiency evaluation in SMED projects

Braglia¹,

Paco

MARRAZZINI³

2023

Preprint

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“…The quality-control concept SMED has been widely used to reduce changeover [18,19]. In this method, the time taken on changeover operations is a key factor.…”

Section: Literature Reviewmentioning

confidence: 99%

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

2022

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Operations management is a key aspect in any manufacturing business. Optimising the management of manufacturing operations allows improvement of the productivity and efficiency of industrial activities. To achieve this, reducing waste from manufacturing processes and, therefore, implementing lean-manufacturing principles, is key. This article presents a case study to reduce waste in changeover processes at a ready-meal manufacturer based in South Yorkshire, UK. We identified a large number of activities as part of the changeover process. We applied the Single Minute Exchange of Dies (SMED) methodology to reduce and, whenever possible, eliminate changeover, and line hopping to further optimise changeover. After implementing improvement measures, changeover time was reduced by nearly 30%, OEE was increased to over 70%, and labour costs were reduced by 10%. This shows how lean principles can aid in implementing more effective and economically sustainable manufacturing operations.

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“…However, OEE integrates the availability of machines and equipment into its calculation, so downtimes due to product changes must be fast [ 39 ], and this can be solved by the application of QS [ 39 ], although there may be many other factors (Junior et al, 2022). For Haddad et al [ 40 ], in the case of the QS, having machines and a clean space facilitates quick changeovers and increases machine availability levels by decreasing downtime, which in turn increases OEE levels and economic savings, so the following hypothesis is proposed: H 3 : Quick setup has a direct and positive impact on OEE.…”

Section: Literature Review and Hypothesismentioning

confidence: 99%

Relationship between lean manufacturing tools and their sustainable economic benefits

Díaz-Reza

Alcaráz

Figueroa

et al. 2022

Int J Adv Manuf Technol

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Traditionally, the isolated relationship of total preventive maintenance (TPM), quick setup (QS), overall equipment effectiveness (OEE), and one-piece flow (OPF) with economic sustainability (ESU) has been investigated; however, these lean manufacturing (LM) tools are implemented together into production systems, and traditional research does not report their relationships and interactions. To contribute to this gap, this paper integrates all those variables in a structural equation model (SEM), which are related by seven hypotheses that are validated using the partial least squares (PLS) technique using information from 176 responses to a questionnaire applied to the Mexican maquiladora industry. Additionally, a sensitivity analysis has been carried out to determine the probability of occurrence at high and low implementation levels for all variables when they occur in isolation, jointly and conditionally. Findings indicate that TPM is a precursor of QS and OEE, while QS is a precursor of OEE and OPF, OEE is a precursor of OPF and ESU, but also OPF is a precursor of ESU. The sensitivity analysis indicates that low levels of TPM are a risk for reaching adequate levels of OEE and QC, while low levels in OEE and OPF are a risk for reaching adequate ESU levels. Supplementary Information The online version contains supplementary material available at 10.1007/s00170-022-10208-0.

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A novel framework for single-minute exchange of die (SMED) assisted by lean tools

Cited by 22 publications

References 30 publications

A new Lean tool for efficiency evaluation in SMED projects

A new Lean tool for efficiency evaluation in SMED projects

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

Relationship between lean manufacturing tools and their sustainable economic benefits

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