Benefits from a SMED Application in a Punching Machine

This paper presents an application of the SingleMinute 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.

[1]  Geraint W Owen,et al.  Changeover improvement: A maintenance perspective , 2001 .

[2]  B. G. Dale,et al.  Set-up time reduction and mistake proofing methods - A study of application in a small company , 2001, Bus. Process. Manag. J..

[3]  Dinesh Khanduja,et al.  SMED: for quick changeovers in foundry SMEs , 2009 .

[4]  新郷 重夫,et al.  A study of the Toyota production system from an industrial engineering viewpoint , 1989 .

[5]  R. M. Sousa,et al.  An industrial application of resource constrained scheduling for quick changeover , 2009, 2009 IEEE International Conference on Industrial Engineering and Engineering Management.

[6]  Edward J. Hay.  Any machine set-up time can be reduced by 75% , 1987 .

[7]  Geraint W Owen,et al.  A critical evaluation of Shingo's 'SMED' (Single Minute Exchange of Die) methodology , 2000 .

[8]  Berna Ulutas,et al.  An Application of SMED Methodology , 2011 .

[9]  Bengt Klefsjö,et al.  The machine that changed the world , 2008 .

[10]  R. Bohn,et al.  Setup Time Reduction for Electronics Assembly: Combining Simple (SMED) and IT‐Based Methods , 2005 .

[11]  Ronny Fritsche,et al.  Reducing set-up times for improved flexibility in high-mix low-volume electric drives production , 2011, 2011 1st International Electric Drives Production Conference.

[12]  Sven Maričić,et al.  Die casting process assessment using single minute exchange of dies (SMED) method , 2009 .

[13]  新郷 重夫,et al.  A revolution in manufacturing : the SMED system , 1985 .

[14]  Supramaniam Tharisheneprem.  Achieving full fungibility and Quick Changeover by turning knobs in tape and Reel machine by applying SMED theory , 2008, 2008 33rd IEEE/CPMT International Electronics Manufacturing Technology Conference (IEMT).

[15]  大野 耐一,et al.  Toyota production system : beyond large-scale production , 1988 .

[16]  Richard Greatbanks,et al.  Prerequisites for the implementation of the SMED methodology: A study in a textile processing environment , 2001 .

[17]  Dirk Van Goubergen,et al.  Reducing Set-up Times of Manufacturing Lines , 2002 .

[18]  M. Gilmore,et al.  Set‐up reduction in pharmaceutical manufacturing: an action research study , 1996 .