Benefits from a SMED Application in a Punching Machine

Authors: Eric Costa, Sara Bragança, Rui Sousa, Anabela Alves

Abstract:

This paper presents an application of the Single-Minute Exchange of Die (SMED) methodology to a turret punching machine in an elevators company, in Portugal. The work was developed during five months, in the ambit of a master thesis in Industrial Engineering and Management. The Lean Production tool SMED was applied to reduce setup times in order to improve the production flexibility of the machine. The main results obtained were a reduction of 64% in setup time (from 15.1 to 5.4min), 50% in work-in-process amount (from 12.8 to 6.4 days) and 99% in the distance traveled by the operator during the internal period (from 136.7 to 1.7m). These improvements correspond to gains of about €7,315.38 per year.

Keywords: Lean production, setup process, SMED.

Digital Object Identifier (DOI): doi.org/10.5281/zenodo.1088518

References:

[1] R. I. McIntosh, S. J. Culley, A. R. Mileham, and G. W. Owen, "A critical evaluation of Shingo's 'SMED' (Single Minute Exchange of Die) methodology," International Journal of Production Research, vol. 38, pp. 2377-2395, Jul 20 2000.
[2] S. Shingo, A revolution in manufacturing: the SMED system: Productivity Press, 1985.
[3] J. P. Womack, D. T. Jones, and D. Roos, "The Machine That Changed the World: The Story of Lean Production: How Japan’s Secret Weapon in the Global Auto Wars Will Revolutionize Western Industry," New York, NY: Rawson Associates, 1990.
[4] T. Ohno, Toyota production system: beyond large-scale production: Productivity press, 1988.
[5] S. Shingo, A study of the Toyota production system: From an Industrial Engineering Viewpoint: Productivity Press, 1989.
[6] R. I. McIntosh, S. J. Culley, A. R. Mileham, and G. W. Owen, "Changeover improvement: A maintenance perspective," International Journal of Production Economics, vol. 73, pp. 153-163, Sep 21 2001.
[7] D. Van Goubergen and H. Van Landeghem, "Reducing Set-up Times of Manufacturing Lines," 2002.
[8] R. M. Sousa, R. M. Lima, J. D. Carvalho, and A. C. Alves, "An industrial application of resource constrained scheduling for quick changeover," in Industrial Engineering and Engineering Management, 2009. IEEM 2009. IEEE International Conference on, 2009, pp. 189- 193.
[9] E. J. Hay, "Any machine set-up time can be reduced by 75%," Industrial Engineering, vol. 19, pp. 62-67, 1987.
[10] R. T. Pannesi, "Lead time competitiveness in make-to-order manufacturing firm," International Journal of Production Research, vol. 3, pp. 150-163, 1995.
[11] B. Ulutas, "An application of SMED Methodology," World Academy of Science, Engineering and Technology, vol. 79, p. 101, 2011.
[12] M. Gilmore and D. J. Smith, "Set-up reduction in pharmaceutical manufacturing: An action research study," International Journal of Operations & Production Management, vol. 16, pp. 4-&, 1996 1996.
[13] S. C. Trovinger and R. E. Bohn, "Setup time reduction for electronics assembly: Combining simple (SMED) and IT-based methods," Production and Operations Management, vol. 14, pp. 205-217, Sum 2005.
[14] S. Tharisheneprem, "Achieving full fungibility and Quick Changeover by turning knobs in tape and Reel machine by applying SMED theory," in Electronic Manufacturing Technology Symposium (IEMT), 2008 33rd IEEE/CPMT International, 2008, pp. 1-5.
[15] S. Patel, P. Shaw, and B. G. Dale, "Set-up time reduction and mistake proofing methods–A study of application in a small company," Business Process Management Journal, vol. 7, pp. 65-75, 2001.
[16] C. Moxham and R. Greatbanks, "Prerequisites for the implementation of the SMED methodology: A study in a textile processing environment," International Journal of Quality & Reliability Management, vol. 18, pp. 404-414, 2001.
[17] M. Perinic, M. Ikonic, and S. Maricic, "Die casting process assessment using single minute exchange of dies (smed) method," Metalurgija, vol. 48, pp. 199-202, Jul-Sep 2009.
[18] B. J. Singh and D. Khanduja, "SMED: for quick changeovers in foundry SMEs," International Journal of Productivity and Performance Management, vol. 59, pp. 98-116, 2009.
[19] R. Fritsche, "Reducing set-up times for improved flexibility in high-mix low-volume electric drives production," in Electric Drives Production Conference (EDPC), 2011 1st International, 2011, pp. 74-77.