SMED: for quick changeovers in foundry SMEs

Abstract

Purpose -The purpose of this paper is to uncover the significance of quick changeovers in die-casting foundry environments. Design/methodology/approach -The paper gives set-up instructions and guidelines to prepare the standardized set-up procedure without ignoring actual constraints in foundries. It uses a case study in a medium scale piston foundry to generate an integrated set-up reduction approach, utilizing single minute exchange of die (SMED)-based industrial engineering tools to achieve faster set-ups. It describes the feasibility of quick changeovers in foundry small and medium enterprises based on a "SMED" approach. Finally, the paper carries out empirical analysis of the financial/non-financial benefits incurred from set-up reductions. Findings -Set-up activities are a vital part of the production lead-time of any product and so affect overall product cost. Tools like Pareto analysis, root-cause analysis and method study have been used to analyze the existing procedure of set-ups. A SMED approach can help eliminate unwanted activities, externalize the internal activities, if possible and reduce them by simplification or standardization. The application of other tools such as 5S, Poke-Yoke and specific tool-kits are suggested to further reduce set-up times. Originality/value -The paper demonstrates the practical application of SMED showing how it can bring real breakthroughs in productivity to small and medium scale foundries.

Reducing Process Setup in a Smart TV Card Factory

“…Thus, the TRF system makes it possible to reduce setup times, making small batch production feasible, thus obtaining greater flexibility in introducing changes in product structure and faster responses to market changes. In addition, it provides a reduction in crossing times; reduction of inventory levels in process and finished products; cost reduction; reduction of worker efforts; reduction of errors due to machine adjustments and consequently reduction of defects and rework; and increased production capacity in critical resources [3]. Vol: -7 No-11, 2019 International Educative Research Foundation and Publisher © 2019 pg.…”

Evaluation Setup Process on Rotogravure Printing Machine in Oder to Reduce Setup Time

“…Setup time is one of the important parameters used in the manufacturing industry and is a form of input needed for each machine or workstation [8]. The setup involves all activities starting from preparing the machine or workstation to carrying out the next operation, and the type of work, type of machine and both [9]. Reduction Setup theory or method used to shorten setup time.…”

Non-valued Changeover Time Measures for Hiddxen Time Loss in Automotive Mechanical Component Production

“…Furthermore, Van Goubergen and Van Landeghen [15] established that change-overs in product line generally need minutes, hours, or sometimes days to get completed. So, it is crucial to minimize the time to setup by reducing the activities which are not adding value to the overall production [5]. Operational performance can be improved effectively by using the fundamental concept of Just In Time tools like Multi-Skill Employee and 5S particularly to reduce unproductive time in change-over activities that happen due to the lack of suitable operational techniques particularly on change-over activities [13] [16].…”

“…On this matter, the non-value added activities are known as the time between the last product of preceding order being generated that is leaving the procedure and the new up-coming product of next procedure [3] [4]. Singh and Khanduja [5] indicates that setup is the procedure of accomplishment of activities in a certain sequence, which are performed to gain the constraints on production before the beginning of any product manufacturing. Taken together, the nonvalue added activities can never be avoided but steps can be taken to minimize them.…”