Implementation of the Single Minute Exchange of Dies method for reducing changeover time in a hygiene production company

Malindžáková, Marcela; Malindžák, Dušan; Garaj, Patrik

doi:10.24867/ijiem-2021-4-291

Cited by 13 publications

(10 citation statements)

References 13 publications

(17 reference statements)

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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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“…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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“…Single Minute Exchange of Die (SMED) is a methodology used to analyze, reduce, and standardize the changeover time; the changeover is considered a loss, non-productive activity (Naboureh & Safari, 2016). Reducing changeover time leads to a reduction of lead time and ensuring and enhancing competitiveness, as manufacturing loss is related to loss of competitiveness (Malindzakova et al, 2021). Benefits of implementing SMED include cost and waste reduction, increased production capacity and flexibility of the equipment, increased machine efficiency and customer satisfaction (Ribeiro et al, 2022).…”

Section: Single Minute Exchange Of Diementioning

confidence: 99%

“…Thanks to increasing the availability and the efficiency of the production line, SMED allows for increasing the Overall Equipment Effectiveness (Otero & Lopes, 2018;Suryaprakash et al, 2021;Pattaro Jr. et al, 2022). Many kinds of research confirm the implementation of SMED in different countries and industries, e.g., in hygiene production (Malindzakova et al, 2021), automotive (Rosa et al, 2017), plastics industry (Saravanan et al, 2018), or manufacturing (Otero & Lopes, 2018). Antosz & Pacana (2018) studied the effects of SMED on conventional, semi-automatic and automatic production work stands.…”

Section: Single Minute Exchange Of Diementioning

confidence: 99%

“…In this article, we focus on tools such as Single Minute Exchange of Die (SMED) and Total Productive Maintenance (TPM), which are aimed at managing machines and equipment, reducing waste and lead time. Short lead times mean higher flexibility and improved competitive position (Malindzakova et al, 2021;Ribeiro et al, 2022). These tools were chosen concerning their impact on competitiveness and at the same time with regard to the focus of the author's collective.…”

Section: Introductionmentioning

confidence: 99%

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The Impact of Single Minute Exchange of Die and Total Productive Maintenance on Overall Equipment Effectiveness

Ondra¹

2022

JOC

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Due to intense global competition, manufacturing companies need to improve and optimize productivity, increase production and flexibility, and gain competitive advantages. Companies have begun to look for new approaches and strategies in the field of production management. This includes tools like Single Minute Exchange of Die (SMED) and Total Productive Maintenance (TPM), which aim to manage machines and equipment, reduce waste and lead time, and ensure and enhance competitiveness. The main objective of this study is to explore the connection and the context of the use of industrial engineering tools, namely SMED and TPM, and to monitor and evaluate Overall Equipment Effectiveness (OEE) in industrial companies in the Czech Republic. A comprehensive questionnaire survey of 200 companies and a detailed evaluation of the operational performance of 92 companies were carried out from the third quarter of 2019 to the third quarter of 2020. It was found out that 20.5% of companies implemented SMED, 26.5% of companies implemented TPM, and 54.0% of companies did not monitor and evaluate OEE. The research confirms the theoretical link between SMED and OEE and between OEE and TPM. The statistical significance of the use of SMED and TPM separately was not demonstrated. However, the mutual interaction of using TPM and SMED on the OEE level was proved.

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“…7 Malindzakova et al yielded a 30% change time reduction in the hygiene product industry with SMED. 8 Otur et al examined a plastic bottle production line for colour changes with SMED and observed a 60% decrease in time. 9 Abd Suki et al achieved 29.15% higher productivity at a labelling printing company.…”

Section: Introductionmentioning

confidence: 99%

Process improvement and efficiency analysis using the Single‐Minute Exchange of Dies method applied to the set‐up and operation of screen‐printing machines

Emekdar¹,

Açikgöz‐Tufan²,

Şahin³

et al. 2023

Coloration Technology

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Lean manufacturing methods are concerned with simplifying the production process and thus maximising efficiency and minimising wastage. All production processes contain several steps, which include sub‐steps such as cleaning and changing devices and preparing the production areas for later steps. Most of these sub‐steps require that machines are stopped and therefore they must be performed as quickly as possible. This downtime causes a decrease in efficiency, while increasing the costs and production time. Single‐Minute Exchange of Dies (SMED) is a lean manufacturing strategy that has been applied successfully in many sectors to minimise excessive downtime. In this study, the SMED technique is applied in a textile screen‐printing company for the case of changing the screens between each design. The steps are evaluated and designated as either external steps, which are performed without downtime, or internal steps, which take place during downtime. The number of external steps is increased while being decreased for internal steps. Also, the production time decreased by 54% and a 32% increase in efficiency was achieved during the screen‐printing production of a sample t‐shirt.

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Implementation of the Single Minute Exchange of Dies method for reducing changeover time in a hygiene production company

Cited by 13 publications

References 13 publications

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

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

The Impact of Single Minute Exchange of Die and Total Productive Maintenance on Overall Equipment Effectiveness

Process improvement and efficiency analysis using the Single‐Minute Exchange of Dies method applied to the set‐up and operation of screen‐printing machines

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