Optimizing the changeover of packaging machine by implementing single minute exchange of dies in textile manufacturing industry

Today, the majority of firms, particularly in the manufacturing domain, are espousing flexibility with regard to manufacturing an anay of products. The aim is to meet consumers'requirements so as to remain competitive and afloat in the industry. This can be done by ensuring a swift changeover o...

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Main Author:	Rosli, Mohamad Muzammir
Format:	Thesis
Language:	English English
Published:	2016
Subjects:	T Technology (General) TS Manufactures
Online Access:	http://eprints.utem.edu.my/id/eprint/20546/1/Optimizing%20the%20changeover%20of%20packaging%20machine%20by%20implementing%20single%20minute%20exchange%20of%20dies%20in%20textile%20manufacturing%20industry.pdf http://eprints.utem.edu.my/id/eprint/20546/2/Optimizing%20the%20changeover%20of%20packaging%20machine%20by%20implementing%20single%20minute%20exchange%20of%20dies%20in%20textile%20manufacturing%20industry.pdf
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spelling	my-utem-ep.205462022-12-29T16:02:17Z Optimizing the changeover of packaging machine by implementing single minute exchange of dies in textile manufacturing industry 2016 Rosli, Mohamad Muzammir T Technology (General) TS Manufactures Today, the majority of firms, particularly in the manufacturing domain, are espousing flexibility with regard to manufacturing an anay of products. The aim is to meet consumers'requirements so as to remain competitive and afloat in the industry. This can be done by ensuring a swift changeover of the machinery in such a way that the flexibility of response to demand stays unaffected. A textile firm in Melaka, Malaysia has adopted this approach. To achieve this objective, Single Minute Exchange of Dies (SMED) was deployed to enchance the changeover time of its packaging machine.It was noted that the key issue was the absence of lean thinking by workers, which caused much waste in the changeover process, and in turn the changeover time. By deploying SMED, some waste can be decreased or totally eradicated. The SMED framework involved determining the present changeover process, segregating internal and external tasks, converting maximum internal tasks into external ones, and streamlining all changeover tasks. It was observed that all tasks that are part of this procedure were accomplished internally. On analysis, it was ascertained that one of these tasks had the potential to be accomplished externally, and this task was preparation of new base and receiver. Few of the tasks in the changeover process were removed by enhancing the correlation between the operator and technician in charge of the machine. These tasks were changeover preparation, emptying pins from bowl feeder, putting new pins,and preparing for next run.A new jig was devised and fabricated,aiming at replacing the present jig which can only be utilised by one kind or size of packaging box. This jig intended to get rid of the need to prepare other base when various kinds or sizes of pins require to be packaged. To upgrade the improvements, other lean tools were recommended, including 5S and andon. 5S was recommended to enhance the task of preparing base and receiver by installing an indicator or label for quick identification by the technician. Andon was recommended to enhance the correlation between labourers and inform the technicians regarding the changeover. By means of all these enhancements, a new changeover process which is much easier and time saving was produced.It was observed that with the new process, the total changeover time consumed was 9.5 minutes as against 32.1 minutes for the original changeover time,indicating a saving of around 70 percent. To conclude, this study showed that SMED remains one of the most robust and effective tools which can be utilised to attain a swift changeover that is essential for this firm for making flexibility as one of its strong areas. 2016 Thesis http://eprints.utem.edu.my/id/eprint/20546/ http://eprints.utem.edu.my/id/eprint/20546/1/Optimizing%20the%20changeover%20of%20packaging%20machine%20by%20implementing%20single%20minute%20exchange%20of%20dies%20in%20textile%20manufacturing%20industry.pdf text en public http://eprints.utem.edu.my/id/eprint/20546/2/Optimizing%20the%20changeover%20of%20packaging%20machine%20by%20implementing%20single%20minute%20exchange%20of%20dies%20in%20textile%20manufacturing%20industry.pdf text en validuser https://plh.utem.edu.my/cgi-bin/koha/opac-detail.pl?biblionumber=104923 mphil masters Universiti Teknikal Malaysia Melaka Faculty Of Manufacturing Engineering Mohamad, Effendi
institution	Universiti Teknikal Malaysia Melaka
collection	UTeM Repository
language	English English
advisor	Mohamad, Effendi
topic	T Technology (General) TS Manufactures
spellingShingle	T Technology (General) TS Manufactures Rosli, Mohamad Muzammir Optimizing the changeover of packaging machine by implementing single minute exchange of dies in textile manufacturing industry
description	Today, the majority of firms, particularly in the manufacturing domain, are espousing flexibility with regard to manufacturing an anay of products. The aim is to meet consumers'requirements so as to remain competitive and afloat in the industry. This can be done by ensuring a swift changeover of the machinery in such a way that the flexibility of response to demand stays unaffected. A textile firm in Melaka, Malaysia has adopted this approach. To achieve this objective, Single Minute Exchange of Dies (SMED) was deployed to enchance the changeover time of its packaging machine.It was noted that the key issue was the absence of lean thinking by workers, which caused much waste in the changeover process, and in turn the changeover time. By deploying SMED, some waste can be decreased or totally eradicated. The SMED framework involved determining the present changeover process, segregating internal and external tasks, converting maximum internal tasks into external ones, and streamlining all changeover tasks. It was observed that all tasks that are part of this procedure were accomplished internally. On analysis, it was ascertained that one of these tasks had the potential to be accomplished externally, and this task was preparation of new base and receiver. Few of the tasks in the changeover process were removed by enhancing the correlation between the operator and technician in charge of the machine. These tasks were changeover preparation, emptying pins from bowl feeder, putting new pins,and preparing for next run.A new jig was devised and fabricated,aiming at replacing the present jig which can only be utilised by one kind or size of packaging box. This jig intended to get rid of the need to prepare other base when various kinds or sizes of pins require to be packaged. To upgrade the improvements, other lean tools were recommended, including 5S and andon. 5S was recommended to enhance the task of preparing base and receiver by installing an indicator or label for quick identification by the technician. Andon was recommended to enhance the correlation between labourers and inform the technicians regarding the changeover. By means of all these enhancements, a new changeover process which is much easier and time saving was produced.It was observed that with the new process, the total changeover time consumed was 9.5 minutes as against 32.1 minutes for the original changeover time,indicating a saving of around 70 percent. To conclude, this study showed that SMED remains one of the most robust and effective tools which can be utilised to attain a swift changeover that is essential for this firm for making flexibility as one of its strong areas.
format	Thesis
qualification_name	Master of Philosophy (M.Phil.)
qualification_level	Master's degree
author	Rosli, Mohamad Muzammir
author_facet	Rosli, Mohamad Muzammir
author_sort	Rosli, Mohamad Muzammir
title	Optimizing the changeover of packaging machine by implementing single minute exchange of dies in textile manufacturing industry
title_short	Optimizing the changeover of packaging machine by implementing single minute exchange of dies in textile manufacturing industry
title_full	Optimizing the changeover of packaging machine by implementing single minute exchange of dies in textile manufacturing industry
title_fullStr	Optimizing the changeover of packaging machine by implementing single minute exchange of dies in textile manufacturing industry
title_full_unstemmed	Optimizing the changeover of packaging machine by implementing single minute exchange of dies in textile manufacturing industry
title_sort	optimizing the changeover of packaging machine by implementing single minute exchange of dies in textile manufacturing industry
granting_institution	Universiti Teknikal Malaysia Melaka
granting_department	Faculty Of Manufacturing Engineering
publishDate	2016
url	http://eprints.utem.edu.my/id/eprint/20546/1/Optimizing%20the%20changeover%20of%20packaging%20machine%20by%20implementing%20single%20minute%20exchange%20of%20dies%20in%20textile%20manufacturing%20industry.pdf http://eprints.utem.edu.my/id/eprint/20546/2/Optimizing%20the%20changeover%20of%20packaging%20machine%20by%20implementing%20single%20minute%20exchange%20of%20dies%20in%20textile%20manufacturing%20industry.pdf
_version_	1776103108435247104

Optimizing the changeover of packaging machine by implementing single minute exchange of dies in textile manufacturing industry

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