The Single Minute Exchange of Die Methodology in a High-Mix Processing Line

Abstract

Because of turbulence in the economic environment, enterprises must react flexibly to the changing demands of their customers. Thus, a changeover process is required. If an enterprise has a large product portfolio, there are basically only two process options; to integrate production into large batches or to change the production programme frequently. Frequent changes associated with the changeover process of machinery are optimized by using the SMED method. The main goal of this paper is to apply SMED (Single Minute Exchange of Die) to a High-Mix processing line. The case study is undertaken in a flat glass processing company which manufactures hundreds of types of products. The results of the case study demonstrate that it is possible to save up to 30% annually of the time currently spent on changeovers.

A Case Study on Reducing Setup Time Using SMED on a Turning Line

“…They used an integrated setup reduction approach consisting of lean manufacturing techniques such as SMED, Kanban, 5S and Total Productive Maintenance. Filla [16] has applied SMED to High Mixing operations in a flat glass processing company that produces hundreds of products. Soberi and Ahmad [17] proposed a new hybrid method that integrates the original SMED and Analytical Hierarchy Process.…”

Interrelations among SMED Stages: A Causal Model

“…It is advised to have all necessary equipment and tools at hand to perform the setup but also to remove those instruments that will not be required. Sometimes having too many objects at the workstation can cause accidents [23,24]. Similarly, companies should use visual signs to signpost every movement required in each setup operation, although this is only possible if internal and external work are appropriately separated.…”

“…To study the relationship between the Identification Stage and the Transformation Stage of SMED implementation, the second working hypothesis is proposed as follows. Any process improvement methodology using lean techniques such as SMED must take pertinent measurements of the production process [24], since such measurements would allow companies to design an appropriate plan for continuous improvement. For this reason, experts argue that SMED activities to be executed must be measurable and expressed in appropriate units, so that all operators can understand them [25].…”

“…The Separation Stage is also key to successful SMED implementation because, if properly conducted, it becomes easier and faster to move toward the Transformation Stage, at which companies must convert as much internal setup to external as possible [24]. Therefore, to study and test the relationship between the Separation Stage and the Transformation Stage during SMED implementation, the fourth working hypothesis is proposed.…”

Using Tools to Improve Logistics and Production Processes in a Selected Construction Company

“…Tasks and procedures associated with the supply chain are viewed from a project-focused perspective, rather than from a general or standardized perspective, which makes it easier for project managers to focus on specific project results and unique customer requirements (Garcia-Acaraz et al, 2019;Abdallah et al, 2016). The implementation of Lean principles requires the Using Tools to Improve Logistics and Production Processes in a Selected Construction Company 1214 implementation of many typical tools that will improve the functioning of the company (Filla, 2016). In practice, these techniques are usually referred to as Lean Toolbox (Carrizo Moreira and Torres Garcez, 2013).…”