REDUCING THE PRODUCT CHANGEOVER TIME USING SMED & 5S METHODS IN THE INJECTION MOLDING INDUSTRY

Abstract

Along with the increasing market of plastic packaging products resulting from the injection process and the rapid development of existing technology, we need a strategy to be able to continue to meet the customer’s needs and to be able to compete in the industry. One of the strategies that may be employed is Lean. Lean is a concept aimed at eliminating existing waste. One of the implementations of Lean’s concept is the SMED (Single Minute Exchange of Dies) concept. SMED is a concept aimed at reducing the changeover time, so the eliminated time can be used in the production process. P.T. BIL is one of the companies engaged in the production of plastic packaging with an injection process. Problems occurring at P.T. BIL was the absence of a measurement process for changeover time. The Operation Analysis Chart concept was used to analyze the carried-out activities. To optimize activities employing the SMED concept, Analytical Cards were used so that the change over time can be reduced. The 5S concept was applied to support the SMED concept, so the waste in the work area could be eliminated. By implementing the SMED concept, we reduced 18% of the change over time.

Lean-SLP production model to reduce lead time in SMEs in the plastics industry: A Empirical Researh in Peru

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Developing I4.0 Readiness Index for Factory Operation in Indonesia to Enhance INDI 4.0

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Improve Ramp-Up Performance on the Sewing Process in a Sports Shoe Factory Using 8-Disciplines and Lean Manufacturing

“…The concept used in time-related lean production is just in time and SMED (Single Minute Exchange Dies) is associated with model change. In various industries, such as the iron industry, the apparel industry, and the telecommunications panel industry (Gavali, Chavan and Dongre, 2016;Mulyana and Hasibuan, 2017;Singla and Pal, 2017;Zerin, Hossain and Zannat, 2019), SMED is widely used to solve rapid transition problems in the production process (Esa, Rahman and Jamaludin, 2015;Jagtap et al, 2015;Filla, 2016;Gavali, Chavan and Dongre, 2016;Arief and Ikatrinasari, 2018;Syafei and Lokadipati, 2018;Agung and Hasbullah, 2019;Talekar et al, 2019). The application of SMED in the clothing industry had been a success in reducing the replacement time of the model between 0.45-12.6 hours (Singla and Pal, 2017), while the replacement time in the apparel industry had reduced by 283.81 minutes (Zerin, Hossain and Zannat, 2019), It can reduce the retooling time by up to 6 minutes in the food industry (Maalouf and Zaduminska, 2019), it can saved setup time by up to 12 minutes in the pharmaceutical industry (Arief and Ikatrinasari, 2018), it can reduce setup time by up to 9 minutes in the copper cable industry (Setyawan, 2019).…”