Changeover time improvement of pressure die casting machine by single minute exchange of die implementation

Globally, the manufacturing sector has undergone a turbulent period due to the growing in the competition to the existing market. Therefore, companies should improve their productivity by implementing Quick Changeover to cater the issues. With that, a door hardware company in Melaka, Malaysia has im...

Full description

Saved in:

Bibliographic Details
Main Author:	Embok Resa, Mohammad Afif
Format:	Thesis
Language:	English English
Published:	2020
Subjects:	T Technology (General) TS Manufactures
Online Access:	http://eprints.utem.edu.my/id/eprint/25352/2/Changeover%20Time%20Improvement%20Of%20Pressure%20Die%20Casting%20Machine%20By%20Single%20Minute%20Exchange%20Of%20Die%20Implementation.pdf http://eprints.utem.edu.my/id/eprint/25352/1/Changeover%20Time%20Improvement%20Of%20Pressure%20Die%20Casting%20Machine%20By%20Single%20Minute%20Exchange%20Of%20Die%20Implementation.pdf
Tags:	Add Tag No Tags, Be the first to tag this record!

id	my-utem-ep.25352
record_format	uketd_dc
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 Embok Resa, Mohammad Afif Changeover time improvement of pressure die casting machine by single minute exchange of die implementation
description	Globally, the manufacturing sector has undergone a turbulent period due to the growing in the competition to the existing market. Therefore, companies should improve their productivity by implementing Quick Changeover to cater the issues. With that, a door hardware company in Melaka, Malaysia has implemented Single Minutes Exchange of Die (SMED) to reduce the changeover time of its Pressure Die Casting 2 machine. The objectives of this study were to study the existing changeover process, to propose new Standard Operating Procedure (SOP) by streamlining the steps of the existing changeover process and designing quick coupling hoses, and then to validate the new Standard Operating Procedure (SOP) of the changeover process. This study was only attentive on the Pressure Die Casting 2 machine. The complications were identified by using 6-steps of Problem-Solving Method. The wastes of the changeover process were eliminated by implementing SMED which consists of Classification Phase, Separation Phase, Conversion Phase and streamlining all aspects. The internal and external tasks of the changeover process were identified then separated by using a checklist. Some of the internal tasks have been converted to external tasks by execution of pre-preparations of tools. Radical improvements comprise quick coupling hoses, marking at the crane, organize the unused hoses and the improvements of hoses line connections have contributed to the reduction of changeover time. After slight adjustment during SMED implementation, Task 1 (setter) has been eliminated as it was considered as the external task meanwhile Task 17 (setter) has been shifted to Task 8 (operator). As a result, there were 16 tasks done by the setter and 8 tasks done by the operator. After the implementation of SMED, the changeover time reduced as much as 25 minutes from 117 minutes to 92 minutes which is equivalent to 21.37% therefore achieved the initial target of 20% reduction. It is proven very clearly that SMED methodology able to reduce the time of changeover process in Pressure Die Casting 2 machine.
format	Thesis
qualification_name	Master of Philosophy (M.Phil.)
qualification_level	Master's degree
author	Embok Resa, Mohammad Afif
author_facet	Embok Resa, Mohammad Afif
author_sort	Embok Resa, Mohammad Afif
title	Changeover time improvement of pressure die casting machine by single minute exchange of die implementation
title_short	Changeover time improvement of pressure die casting machine by single minute exchange of die implementation
title_full	Changeover time improvement of pressure die casting machine by single minute exchange of die implementation
title_fullStr	Changeover time improvement of pressure die casting machine by single minute exchange of die implementation
title_full_unstemmed	Changeover time improvement of pressure die casting machine by single minute exchange of die implementation
title_sort	changeover time improvement of pressure die casting machine by single minute exchange of die implementation
granting_institution	Universiti Teknikal Malaysia Melaka
granting_department	Faculty of Manufacturing Engineering
publishDate	2020
url	http://eprints.utem.edu.my/id/eprint/25352/2/Changeover%20Time%20Improvement%20Of%20Pressure%20Die%20Casting%20Machine%20By%20Single%20Minute%20Exchange%20Of%20Die%20Implementation.pdf http://eprints.utem.edu.my/id/eprint/25352/1/Changeover%20Time%20Improvement%20Of%20Pressure%20Die%20Casting%20Machine%20By%20Single%20Minute%20Exchange%20Of%20Die%20Implementation.pdf
_version_	1776103127342120960
spelling	my-utem-ep.253522023-07-17T11:52:16Z Changeover time improvement of pressure die casting machine by single minute exchange of die implementation 2020 Embok Resa, Mohammad Afif T Technology (General) TS Manufactures Globally, the manufacturing sector has undergone a turbulent period due to the growing in the competition to the existing market. Therefore, companies should improve their productivity by implementing Quick Changeover to cater the issues. With that, a door hardware company in Melaka, Malaysia has implemented Single Minutes Exchange of Die (SMED) to reduce the changeover time of its Pressure Die Casting 2 machine. The objectives of this study were to study the existing changeover process, to propose new Standard Operating Procedure (SOP) by streamlining the steps of the existing changeover process and designing quick coupling hoses, and then to validate the new Standard Operating Procedure (SOP) of the changeover process. This study was only attentive on the Pressure Die Casting 2 machine. The complications were identified by using 6-steps of Problem-Solving Method. The wastes of the changeover process were eliminated by implementing SMED which consists of Classification Phase, Separation Phase, Conversion Phase and streamlining all aspects. The internal and external tasks of the changeover process were identified then separated by using a checklist. Some of the internal tasks have been converted to external tasks by execution of pre-preparations of tools. Radical improvements comprise quick coupling hoses, marking at the crane, organize the unused hoses and the improvements of hoses line connections have contributed to the reduction of changeover time. After slight adjustment during SMED implementation, Task 1 (setter) has been eliminated as it was considered as the external task meanwhile Task 17 (setter) has been shifted to Task 8 (operator). As a result, there were 16 tasks done by the setter and 8 tasks done by the operator. After the implementation of SMED, the changeover time reduced as much as 25 minutes from 117 minutes to 92 minutes which is equivalent to 21.37% therefore achieved the initial target of 20% reduction. It is proven very clearly that SMED methodology able to reduce the time of changeover process in Pressure Die Casting 2 machine. 2020 Thesis http://eprints.utem.edu.my/id/eprint/25352/ http://eprints.utem.edu.my/id/eprint/25352/2/Changeover%20Time%20Improvement%20Of%20Pressure%20Die%20Casting%20Machine%20By%20Single%20Minute%20Exchange%20Of%20Die%20Implementation.pdf text en validuser http://eprints.utem.edu.my/id/eprint/25352/1/Changeover%20Time%20Improvement%20Of%20Pressure%20Die%20Casting%20Machine%20By%20Single%20Minute%20Exchange%20Of%20Die%20Implementation.pdf text en public https://plh.utem.edu.my/cgi-bin/koha/opac-detail.pl?biblionumber=119162 mphil masters Universiti Teknikal Malaysia Melaka Faculty of Manufacturing Engineering Mohamad, Effendi 1. Ali, M., Aladeemy, M., Abdelhadi, A., & Mumani, A. (2013). A proposed approach for setup time reduction through integrating conventional SMED method with multiple criteria decision-making techniques. Computers & Industrial Engineering, 66(2), 461–469. https://doi.org/10.1016/j.cie.2013.07.011 2. Antosz, K., & Pacana, A. (2018). Comparative Analysis of the Implementation of the SMED 3. Method on Selected Production Stands. 3651, 276–282. 4. Arief, R. K., & Nurlaila, Q. (2019). Setup time efficiencies of quick die change system in metal stamping process. https://doi.org/10.1088/1757-899X/602/1/012040 5. Basri, A. Q., Mohamed, N. M. Z. N., Yasir, K. A. S. H. M., Fazi, H. M., & Fudzin, A. F. (2019). The validation of productivity on the changeover activity at the automotive stamping press line by comparing the embedded SMED frame-work versus SMED approach: A witness simulation case study. https://doi.org/10.1088/1757- 899X/469/1/012005 6. Bevilacqua, M., Ciarapica, F. E., Sanctis, I. De, Mazzuto, G., & Paciarotti, C. (2015). A Changeover Time Reduction through an integration of lean practices: A case study from pharmaceutical sector. 1(May 2014), 22–34. https://doi.org/10.1108/AA-05- 2014-035 7. Brito, M., Ramos, A. L., Carneiro, P., & Gonçalves, M. A. (2017). Combining SMED methodology and ergonomics for reduction of setup in a International turning and production area. Procedia Manufacturing, 13, 1112–1119. https://doi.org/10.1016/j.promfg.2017.09.172 8. Cakmakci, M. (2009). Process improvement: performance analysis of the setup time reduction-SMED in the automobile industry. 168–169. https://doi.org/10.1007/s00170- 008-1434-4 9. Chen, S., Fan, S., Xiong, J., & Zhang, W. (2017). The Design of JMP/SAP Based Six Sigma Management System and its Application in SMED. Procedia Engineering, 174, 416– 424. https://doi.org/10.1016/j.proeng.2017.01.161 10. Chronéer, D., & Wallström, P. (2016). Exploring Waste and Value in a Lean Context. International Journal of Business and Management, 11(10), 282. https://doi.org/10.5539/ijbm.v11n10p282 11. Dave, Y., & Sohani, N. (2012). Single Minute Exchange of Die: Literature Review. 3(2), 29. de Souza, R. V. B., & Carpinetti, L. C. R. (2014). A FMEA-based approach to prioritize waste reduction in lean implementation. International Journal of Quality and Reliability Management, 31(4), 346–366. https://doi.org/10.1108/IJQRM-05-2012- 0058 12. Diaby, M. (1995). Optimal setup time reduction for a single product with dynamic demands. 13. Díaz-reza, J. R., García-alcaraz, J. L., Martínez-loya, V., Blanco-fernández, J., Jiménezmacías, E., & Avelar-sosa, L. (2016). The Effect of SMED on Benefits Gained in Maquiladora Industry. 1–18. https://doi.org/10.3390/su8121237 14. Díaz-reza, J. R., García-alcaraz, J. L., Mendoza-fong, J. R., Martínez-loya, V., Macías, E. J., & Blanco-fernández, J. (2017). Interrelations among SMED Stages : A Causal Model. 2017. 15. Eaknipitsari, K., & Chutima, P. (2019). Operational Efficiency Improvement of Ply Cutting Machine for Aircraft Tires. 0–6. https://doi.org/10.1088/1757-899X/576/1/012020 16. Ekincioğlu, C., & Boran, S. (2018). SMED methodology based on fuzzy Taguchi method. 31(6), 867–878. https://doi.org/10.1108/JEIM-01-2017-0019 17. Eldein, S. A. S., & Sobhi, N. (2019). Waste reduction by linear programming optimizing. https://doi.org/10.1088/1757-899X/610/1/012079 18. Garg, G. (2016). Execution of single minute exchange of die on corrugation machine in cardboard box manufacturing company: A Case Study. 2(2), 133–145. 19. Godina, R., Pimentel, C., Silva, F. J. G., & Matias, J. C. O. (2018). A Structural Literature Review of the Single Minute Exchange of Die. Procedia Manufacturing, 17, 783–790. https://doi.org/10.1016/j.promfg.2018.10.129 20. Hermel, D., Medina, O., & Shvalb, N. (2017). A note on estimating minimal changeover time. Cogent Engineering, 27(1), 1–7. https://doi.org/10.1080/23311916.2017.1330911 21. Indrawati, S., Pratiwi, M. E., & Azzam, A. (2018). The effectiveness of single minute exchange of dies for lean changeover process in printing industry. 01064, 0–4. 22. Karam, A., Karam, A., Cristina, V., & Trade-off, H. R. (2018). The contribution of Society lean manufacturing tools changeover time decreases in the pharmaceutical industry . A SMED project. Procedia Manufacturing, 22, 886–892. https://doi.org/10.1016/j.promfg.2018.03.125 23. Karasu, M. K., Cakmakci, M., Cakiroglu, M. B., & Ayva, E. (2014). Improvement of changeover times via Taguchi empowered SMED / case study on injection molding production. MEASUREMENT, 47, 741–748. https://doi.org/10.1016/j.measurement.2013.09.035 24. Karim, R. (2013). Impact of Changeover time on productivity: A case study. 06, 42–48. 25. Kholil, M., Alfa, B. N., & Supriyanto. (2018). Optimization of Production Process Time with Network/PERT Analysis Technique and SMED Method. https://doi.org/10.1088/1757-899X/453/1/012050 26. Khusaini, N. S., Jaffar, A., & Yusoff, N. (2014). A survey on lean manufacturing tools implementation in malaysian food and beverages industry using rasch model. Advanced Materials Research, 845, 642–646. https://doi.org/10.4028/www.scientific.net/AMR.845.642 27. King, P. L. (2009). Improved flow through shorter product changeovers. 1–8. 28. Kolanjiappan, S. (2015). Innovative Approach in Introducing Lean Manufacturing Tools in Maintenance of Aircraft. Applied Mechanics and Materials, 766–767, 1190–1195. https://doi.org/10.4028/www.scientific.net/amm.766-767.1190 29. Kumar, K., & Aouam, T. (2018). Effect of setup time reduction on supply chain safety stocks. Journal of Manufacturing Systems, 49(January), 1–15. https://doi.org/10.1016/j.jmsy.2018.08.001 30. Lipiak, J. (2017). Methodology for Assessing the Factors Affecting the Quality and Efficiency of Flexographic Printing Process. Procedia Engineering, 182, 403–411. https://doi.org/10.1016/j.proeng.2017.03.122 31. Lozano, J, Martínez, E., Jiménez, E., Blanco, J., Martínez, E., Jiménez, E., & Blanco, J. (2019). The Management of Operations Centerline-SMED integration for machine changeovers improvement in food industry. Production Planning & Control, 0(0), 1– 15. https://doi.org/10.1080/09537287.2019.1582110 32. Lozano, Jorge, Saenz-diez, J. C., Martinez, E., Jimenez, E., & Blanco, J. (2017). Integration of the SMED for the improvement of the supply chain management of spare parts in the food sector. 2017(8), 370–379. https://doi.org/10.17221/69/2016-AGRICECON 33. Maalouf, M. M., & Zaduminska, M. (2019). A Case Study of VSM And SMED In the Food Processing Industry. 10(2), 60–68. https://doi.org/10.24425/mper.2019.129569 34. Martins, M., Martins, M., Godina, R., Pimentel, C., Silva, F. J. G., & Matias, J. C. O. (2018). A Practical Study of the Application of SMED to Electron-beam. Procedia Manufacturing, 17, 647–654. https://doi.org/10.1016/j.promfg.2018.10.113 35. Mcintosh, R. I., Culley, S. J., & Mileham, A. R. (2000). A critical evaluation of Shingo’s “SMED” (Single Minute Exchange of Die) methodology. December 2014, 37–41. https://doi.org/10.1080/00207540050031823 36. Monden, Y. (1994). Reduction of Setup Time- Concepts and Techniques. 121–129. 37. Moreira, A. C., Campos, G., & Pais, S. (2011). Single Minute Exchange of Die. A Case Study Implementation. 6(1). 38. Moxham, C., & Greatbanks, R. (2000). Prerequisites for the implementation of the SMED methodology environment. 39. Nallusamy, S., & Saravanan, V. (2016). Lean tools execution in a small scale manufacturing industry for productivity improvement- a case study. Indian Journal of Science and Technology, 9(35). https://doi.org/10.17485/ijst/2016/v9i35/100162 40. Norzaimi, M., & Solihin, M. S. (2014). The Effectiveness of the Single Minute Exchange of Die (SMED) Technique for the Productivity Improvement. 466, 1144–1148. https://doi.org/10.4028/www.scientific.net/AMM.465-466.1144 41. Ohta, H., & Nakamura, M. (2002). Cell formation with reduction in setup times. 42. 42. Otero, E., & Lopes, I. (2018). Productivity Improvement of a Production Line Through Quick Changeover Concept – A Case Study. 0. https://doi.org/10.3233/978-1-61499- 898-3-897 43. Pavnaskar, S. J., Gershenson, J. K., & Jambekar, A. B. (2003). Classification scheme for lean manufacturing tools. International Journal of Production Research, 41(13), 3075– 3090. https://doi.org/10.1080/0020754021000049817 44. Peter, O. (2010). Extending the technology envelope of equipment fungibility with Single Minute Exchange Die (SMED) Novel Solution. 4–7. 45. Prasad, S., Khanduja, D., & Sharma, S. K. (2018). A study on implementation of lean manufacturing in Indian foundry industry by analysing lean waste issues. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 232(2), 371–378. https://doi.org/10.1177/0954405416640169 46. Pratsini, E. (1998). Learning Complementarity and Setup Time Reduction. 25(5), 397–405. 47. Pyreddy, V. R., Kim, S. L., & Banerjee, A. (2007). Optimal investment in setup reduction for finite horizon periodic review inventory system under deterministic time varying demand. October 2014, 37–41. https://doi.org/10.1080/09537289608930377 48. Ribeiro, R. B., Souza, J. De, Beluco, A., Biehl, L. V., Luiz, J., Medeiros, B., Sporket, F., Rossini, E. G., Augusto, F., Do, D., & Li, Y. (2019). Application of the single-minute exchange of die system to the CNC sector of a shoe mold company. Cogent Engineering, 6(1), 1–11. https://doi.org/10.1080/23311916.2019.1606376 49. Rosa, C., Silva, F. J. G., Ferreira, L. P., & Campilho, R. (2017). SMED methodology: The reduction of setup for Steel Wire-Rope assembly lines in Conference the automotive industry. Procedia Manufacturing, 13, 1034–1042. https://doi.org/10.1016/j.promfg.2017.09.110 50. Samaddar, S. (2001). The effect of setup time reduction on its variance. 29, 243–247. 51. Samaddar, S., & Kaul, T. (2016). Effects of Setup and Processing Time Reductions on WIP in the JIT Production Systems. 41(7), 1263–1265. 52. Santiago, F., & Agustin, R. O. (1996). Single-Minute Exchange of Die. m, 214–217. 53. Singh, B. J., & Khanduja, D. (2009). SMED: for quick changeovers in foundry SMEs. 54. Singh, B. J., & Khanduja, D. (2011). Design for set-ups: A step towards Quick Changeovers in Foundries. 1(4), 402–422. 55. Singh, J., Singh, H., & Singh, I. (2018). SMED for quick changeover in manufacturing industry – A case study. 25(7), 2065–2088. https://doi.org/10.1108/BIJ-05-2017-0122 56. Skotnicka-zasadzień, B., & Gębalska-kwiecień, A. (2018). Improving the efficiency of the production process using SMED. 01002. 57. Sousa, E., Silva, F. J. G., Ferreira, L. P., Pereira, M. T., Gouveia, R., & Silva, R. P. (2018). Applying SMED methodology in cork stoppers production. Procedia Manufacturing, 17, 611–622. https://doi.org/10.1016/j.promfg.2018.10.103 58. Sousa, R. M., Lima, R. M., Carvalho, J. D., & Alves, A. C. (2009). An Industrial Application of Resource Constrained Scheduling for Quick Changeover. 189–193. 59. Sugarindra, M., Ikhwan, M., & Suryoputro, M. R. (2019). Single Minute Exchange of Dies as The Solution on Setup Processes Optimization by Decreasing Changeover Time, A Case Study in Automotive Part Industry. https://doi.org/10.1088/1757- 899X/598/1/012026 60. Tataroğlu, D., Dalkıran, R., Sezen, S., Kesikburun, D., & Kazançoğlu, Y. (2019). Model Sequencing and Changeover Time Reduction in Mixed Model Assembly Line. 1, 898– 913. https://doi.org/10.1007/978-3-319-92267-6 61. Tekin, M., Arslandere, M., Etlioğlu, M., & Koyuncuoğlu, Ö. (2019). An Application of SMED and Jidoka in Lean Production (Vol. 1). Springer International Publishing. https://doi.org/10.1007/978-3-319-92267-6 62. Tharisheneprem, S. (2008). Achieving Full Fungibility and Quick Changeover By Turning Knobs In Tape and Reel Machine By Applying SMED Theory. M. 63. Trevino, J., Hurley, B. J., & Friedrich, W. (1993). A mathematical model for the economic justification of setup time reduction. 31(November 2014), 37–41. https://doi.org/10.1080/00207549308956720 64. Trovinger, S. C., & Bohn, R. E. (2005). Setup Time Reduction for Electronics Assembly: Combining Simple (SMED) and IT-Based Methods. 14(2), 205–217. 65. Wang, S. S., Chiou, C. C., & Luong, H. T. (2019). Application of SMED Methodology and Scheduling in High-Mix Low Volume Production Model to Reduce Setup Time : A Case of S Company. https://doi.org/10.1088/1757-899X/598/1/012058 66. Wang, T., & Song, J. (2007). The economic justification of setup time reduction under variable demand. December 2014, 37–41. https://doi.org/10.1080/00207729808929594 67. Yang, J., & Deane, R. H. (1993). Setup time reduction and competitive advantage in a closed manufacturing cell. 69, 413–423.

Changeover time improvement of pressure die casting machine by single minute exchange of die implementation

Similar Items