Revitalising the setup reduction activities in Operations Management

Pacheco, Diego Augusto de Jesus; Heidrich, Giovana Di Giorgio

doi:10.1080/09537287.2021.1964881

Cited by 8 publications

(4 citation statements)

References 72 publications

(101 reference statements)

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“…Brito and Gonçalves [18] introduced the ErgoSMED to integrate SMED with Ergonomics, in order to simultaneously improve setup times and workers' conditions. Pacheco et al [19] proposed the SMED-presetting by introducing a dedicated presetting department with the responsibility to manage and execute all external activities.…”

Section: Literature Reviewmentioning

confidence: 99%

The Human-Centric SMED

Fonda

Meneghetti

2022

Sustainability

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The Human-Centric SMED (H-SMED) is an evolution of the classical methodology introduced by Shingo to manage the setup process, which is particularly suitable for companies where the setup involves activities with high human content, that can be hardly transformed into external operations to be performed during the machine uptime. The H-SMED integrates Industry 4.0 tools, as the MES Data Analysis, Lean Management and Ergonomics with a new attention to the centrality of workers, in order to guide the transition towards the next Industry 5.0. The H-SMED methodology is developed into four phases, devolved to: (1) understanding the changeover process; (2) identifying potential improvements; (3) moving from proposal to practice; (4) training and control, in a continuous improvement cycle. The case study of a world-wide known company in the fashion eyewear industry is proposed to validate the framework, reporting a 44% reduction of setup duration.

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Section: Literature Reviewmentioning

confidence: 99%

The Human-Centric SMED

Fonda

Meneghetti

2022

Sustainability

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“…First, the As Is values were simulated and the number of replicates was calculated under the empirical formula based on the average and the average interval width as in ( 7) [31] where NO indicates the optimum number of replicates, NI is the initial number of replicates that is usually 30, H indicates the half-interval, C indicates the confidence percentage that in this case is 10% and X means the mean of the set of replications. (7) In the case of As Is maintenance times, 30 sample runs were performed and the optimal number of samples for the average was calculated using confidence interval's formula [31] knowing that the average MTTR is 7.1317 hours, and the average width of the interval is 0.0141 hours. Finally, it was obtained that the number of replicates needed is 1 which is less than 30 therefore the result is accepted.…”

Section: Commissioningmentioning

confidence: 99%

“…For example, SMED was combined with Pre-setting systems (anticipation of device settings) to reduce set-up times in a semi-automated company. As a consequence, the OEE of the entire line increased by 17% and set-up times were reduced by 87% [7].…”

Section: Introductionmentioning

confidence: 99%

Model based on TPM to increase the overall efficiency of equipment in an oil company

Herrera-Uribe,

Rivero-Davila,

Saenz-Moron

2023

Proceedings of the 21th LACCEI International Multi-Conference for Engineering, Education and Technology (LACCEI 2023): “Leaders

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The palm oil industry accounts for 33% of vegetable oil production worldwide and has seen an increase in demand in recent years. Despite this, demand in Peru cannot be met because, in many companies, the efficiency of the machines is far below the ideal indicator of 85%. In the company under study, located in the Ucayali-Peru region, the overall equipment efficiency (OEE) is 73.27%, implying that the machinery is not adequately utilized. In that sense, this article shares a real experience of the palm oil industry for an improvement project evaluated with the OEE indicator through the Total Productive Maintenance (TPM), Single-Minute Exchange of Die (SMED) methodologies, among other engineering tools. The final objective is to achieve an improvement in the OEE metric up to the World-Class category of 85%. After simulating the proposed model in Arena taking as indicators the MTTR (Mean time to repair), Set-up time and downtime, a new improved OEE was calculated, which meant an increase of 14.97%, with an availability of 2.96% and a yield of 12.59%. The verdicts of this labor exposed the profit of TPM application in real world oil companies.

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“…Single-Minute Exchange of Die (SMED) is fundamental tool for improving flexibility in production processes [3]. SMED is part of the lean tools, which aim to reduce no-value-added activities in the production system.…”

Section: Introductionmentioning

confidence: 99%

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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Revitalising the setup reduction activities in Operations Management

Abstract: This is the accepted manuscript (post-print version) of the article.Contentwise, the accepted manuscript version is identical to the final published version, but there may be differences in typography and layout.

Cited by 8 publications

References 72 publications

The Human-Centric SMED

The Human-Centric SMED

Model based on TPM to increase the overall efficiency of equipment in an oil company

A new Lean tool for efficiency evaluation in SMED projects

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