Productivity Enhancement by Reducing Setup TimeSMEDCase study in the Automobile factory

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Glob Journ of Researches in Engineering Mechanic an Mechanics Engineering Volume 12 Issue 5 Version 1. Y ear 212 Type: Double Blin Peer Reviewe Internation Research Journ Publisher: Glob Journs Inc.

improvements. SMED reuces the non-prouctive time by streamlining an stanarizing the operations for exchange tools, using simple techniques an easy applications.

1 Glob Journ of Researches in Engineering Mechanic an Mechanics Engineering Volume 12 Issue 5 Version 1. Y ear 212 Type: Double Blin Peer Reviewe Internation Research Journ Publisher: Glob Journs Inc. (USA) Online ISSN: Print ISSN: Prouctivity Enhancement by Reucing Setup - SMED: Case stuy in the Automobile factory M. S. Desai Deogiri Institute of Engineering an Management Stuies Aurangaba ( M.S.) Inia. Abstract - The Single Minute Exchange of Die (SMED) is one important lean tool to reuce waste an improve flexibility in manufacturing processes lowing lot size reuction an manufacturing flow improvements. SMED reuces the non-prouctive time by streamlining an stanarizing the operations for exchange tools, using simple techniques an easy applications. However the process oesn t give the specific actions to implement which can result in overlooking improvements. To overcome this, common statistic an inustri engineering tools can be integrate in the SMED approach to improve SMED implementation results. Keywors : Lean Manufacturing, SMED, Changeover. Intern an extern setups. GJRE-A Classification : FOR Coe : Prouctivity Enhancement by Reucing Setup SMEDCase stuy in the Automobile factory Strictly as per the compliance an regulations of: 212 M. S. Desai. This is a research/review paper, istribute uner the terms of the Creative Commons Attribution- Noncommerci 3. Unporte License permitting l non commerci use, istribution, an reprouction in any meium, provie the origin work is properly cite.

2 Prouctivity Enhancement by Reucing Setup - SMED: Case stuy in the Automobile factory M. S. Desai Abstract - The Single Minute Exchange of Die (SMED) is one important lean tool to reuce waste an improve flexibility in manufacturing processes lowing lot size reuction an manufacturing flow improvements. SMED reuces the nonprouctive time by streamlining an stanarizing the operations for exchange tools, using simple techniques an easy applications. However the process oesn t give the specific actions to implement which can result in overlooking improvements. To overcome this, common statistic an inustri engineering tools can be integrate in the SMED approach to improve SMED implementation results. In the present work, experiments were carrie out to reuce the setup time an tool change time this are important factors which will take lot of time of the prouction in an automobile factory. The applicability of the propose SMED approach was teste for shaping machines changeovers in the automotive inustry. The implementation has enable reuction in setup time, through company's intern resources reorganizations without the nee for significant investment. Keywors : Lean Manufacturing, SMED, Changeover. Intern an extern setups. Author : Assistant Professor, Department of Mechanic Engineering, Deogiri Institute of Engineering an Management Stuies Aurangaba ( M.S.) Inia. mukeshsesai@gmail.com I. Introuction T he SMED system is a theory an set of techniques that make it possible to perform equipment setup an changeover operations in uner 1 min. SMED improves setup process an provie a setup time reuction up to 9% with moerate investments. Setup operation is the preparation or after ajustment that is performe once before an once after each lot is processe [1]. Shingo ivies the setup operation into two parts: Intern setup an extern setup. Intern setup is that setup operation that can be one only when the machine is shut own (attaching or removing the ies). Extern setup is that setup operation that can be one when the machine is still running. These operations can be performe either before or after the machine is shut own. For example getting the equipment reay for the setup operation before the machine is shut own. The setup perio is constitute by intern setup an extern setup. During the intern setup there is no prouction. In the run-up perio reajustments an tri prouctions are taking place. This perio terminates when full output capacity is reache. SMED system inclues three main steps. These steps are as follows: a) Separating Intern an Extern Setup At this step an important question must be aske for each setup. Do I have to shut the machine own to perform this? The answer helps us in istinguishing between intern an extern setup. This step can reuce the setup time by as much as 3 to 5 percent. The three techniques that SMED uses at this step are: Check lists, function checks, an improve transport of ies an other parts. b) Converting Intern Setup to Extern Setup In orer to achieve the single igit setup time objective SMED introuces this step. At this step intern setup activities trie to be converte to extern activities. So the tot time that the machine is shut own will be reuce. Avance preparation of operating conitions, function stanarization, an use of intermeiary jigs are the techniques to support the secon step. c) Streamlining l Aspects of the Setup Operation At this step specific principles are applie to shorten the setup times. Implementing parlel operations, using function clamps, eliminating ajustment an mechanization techniques are use to further setup time reuction.[1]. II. Methoology The researcher observe three complete setups, in aition to the one in the manufacturing cell, an sever parti set-ups. The set-ups have been evuate to examine the type of improvements which can be mae using the SMED methoology. The observations were unertaken using manu means employing a stanarize recoring an anysis sheet. The Factory ha not use vieo techniques to recor set-ups an a ecision was taken not to employ this metho as it was consiere this woul prevent operators from cooperating in the stuy. The first step in the implementation of SMED is to separate intern 15 Volume XII Issue V Version I ( A ) Glob Journ of Researches in Engineering 212 Glob Journs Inc. (US)

3 Prouctivity Enhancement by Reucing Setup SMED: Case stuy in the Automobile factory 16 Volume XII Issue V Version I (activities which can only be carrie out when the machine is stoppe) an extern (activities which can be carrie out when the machine is operating) setup activities. Once the intern an extern activities are ientifie an separate a checklist can be mae of l the parts an steps which shoul be carrie out externly uring the current an preceing operations. The checklist of the set-up proceure which has been evelope for the CNC shaping machine is given in Table 1, saving an estimate 3-35 minutes. Base on the set-ups observe, there are numerous other activities that nee to be eliminate, which are contributing to longer set-up times. For example, as changeover time was not regare as a lost prouction opportunity there was a very relaxe approach by operation personnel to the changeover operation. Operators were so keeping tools an s in their person lockers so that they woul be close to han when neee. It was so observe that the grining of cutting tool tips was not carrie out on time. In aition, the computer program was not upate an this coul potentily lea to an incorrect set-up an therefore elays. Another problem was that the machines use metric measurements whereas the scheules use imperi figures; this meant that operators ha to convert the imperi figures into metric, thus increasing the set-up proceure. It is estimate that by tackling these types of problems an extra 1-15 minutes woul be save on the tot set-up times. The secon stage in Shingo s SMED methoology is to convert intern to extern set-up activities. The height of the machine tables coul be fixe an the istance to the cutting tip set at the appropriate level. The imensions of the various components an jig coul be etermine an contact jigs, compensating for height, coul be mounte an set on the table so that the Cutting surface woul be at the appropriate level. The horizont an vertic imensions of the contact jigs coul be stanarize by locating them against stops set into the table, enabling the operators to centre the component more easily. These improvements woul not only make the set-ups easier for the machine operators but they will so reuce the set-up times by up to 15 minutes. To facilitate these improvements spacer jigs woul have to be mae. They are thinner than the main jig plates, making them easier to transport. Another option for the smler components is to use intermeiary jigs, which involve the use of two stanarize jig plates of the appropriate size an shape. When the component attache to one of the plates is being processe, the next component can be centere an attache to the other jig. When the first component is finishe, this secon jig, together with the attache component, can be mounte on the machine. From the set-ups observe it was foun that operators spen consierable time attaching an fastening jigs an components, an unertaking the necessary checks, an in some cases these fastenings were problematic. ( A ) Glob Journ of Researches in Engineering Sr.N o Activities 1 To prepare trolley for setup 2 Take a Allan key 3 Rotate the 4 Remove the tie ro 5 Remove the burrs with the help of Allan key 6 Remove the s bolts (Sec) On Setup time of shaping machine for the part no Name of Machine: BA 4156; LORENZ GEAR Name of Fixture: RE 332 (Sec) On (Sec) On Interna l Activit y Externa l Activity Extern Intern Intern Intern Intern Intern Moificatio n Remark After After After Remove Intern Glob Journs Inc. (US)

4 Prouctivity Enhancement by Reucing Setup SMED: Case stuy in the Automobile factory the previous 8 Remove the burrs from 9 Remove the insert ro of 1 Clean the hole or Remove the burrs from base plate 11 Take new Intern Intern Intern Extern Rotate the base plate 13 To clean the new by air 14 Clean the base plate 15 To take i inicator with magnetic stan 16 To fixe & ajust the collector 17 To fixe the new 18 To fixe the bolts of 19 To rotate, tight & ajust the 2 To fixe the stan of i inicator Intern Extern Intern Extern Intern Intern Intern Intern Intern Glob Journ of Researches in Engineering ( A ) Volume XII Issue V Version I 212 Glob Journs Inc. (US)

5 Prouctivity Enhancement by Reucing Setup SMED: Case stuy in the Automobile factory 21 To check the run-out of tie ro Intern ( A ) Volume XII Issue V Version I 22 To rotate, tight & ajust the s bolts w.r.to run out 23 To remove the i inicator 24 To fix the bottom bolts of 25 To fixe an ajust the height of tie ro 26 To fix the job & fix the cap 27 To set the machine parameter Tot time (sec ) Tot time (Min ) Intern Intern Intern Intern Intern Intern Design the fixe/ eicate tie ro Very Critic Activity Extern Glob Journ of Researches in Engineering Table 2.1 : Worksheet anysis showing the origin an improve setup time of Machine BA 4156; Lorenz gear The following are the type of errors observe uring the stuy which inicate the potenti for further mistake proofing: Errors ue to absentmineness an those mae without knowing how they have happene (e.g. operators using the wrong equipment or tools). Errors ue to a lack of concentration (e.g. operators overlooking the nee to properly tighten clamps, screws, an tools, etc.). Errors ue to unsuitable instructions or work stanars. More than one operator commente that they foun it ifficult to ahere to rules an stanars (e.g. a measurement may be left to an operator s iscretion ± the imperi/metric issue mentione earlier is a case in point). Errors which occur ue to equipment running ifferently than expecte (e.g. machines mfunctioning without arming). Errors arising from operators misjuging a situation. The supplier coul so communicate with the operator to confirm the paperwork is correct. Prouction control shoul so proofrea the paperwork to ientify an eliminate the errors before this is issue to the shop floor. Chase an Stewart (1994) recommene task an tangible poka yokes to mistake-proof services such as these. The management an control of materis is so critic to set-up reuction an the following problems were observe: (1) Operators were unable to fin tools, clamps, etc. (2) Difficulties were encountere in retrieving jigs from their point of storage. For example: sometimes a forklift river coul not be foun, which meant that a set-up coul not procee; an It was a time-consuming task getting the jig plates off the shelves an putting them away once the operation ha been complete. (3) Tools, jigs, etc. were not put away in the correct place. (4) Operators felt that there was a lack of esk an storage space on which to put tools, clamps, etc. 212 Glob Journs Inc. (US)

6 Prouctivity Enhancement by Reucing Setup SMED: Case stuy in the Automobile factory (5) Jig plates were misplace on shelves an as a consequence they were not easy to locate when require. (6) Raw materis not arriving on time. (7) Finishe components or work-in-progress taking up vuable space. These types of problems result in longer set-up times an greater opportunity for errors an mistakes. III. Discussion on Finings During the interviews the Gener Manager, prouction manager an other mile managers inicate that they wante to reuce set-up times an errors. The interviews unertaken with operators inicate that this interest has not filtere through to the shop floor. The Factory will not be able to achieve singleminute set-ups an zero efects unless awareness of the importance of this is raise. Management must: unerstan an believe in the link between ``oing things right at first time & ways an the Factory s business strategy; unerstan the practicities of set-up time reuction an mistake proofing an be able to communicate the principles an techniques to l employees; participate in the problem-solving process to reuce set-ups an eliminate errors; formulate an maintain a clear iea of what set-up time reuction an mistake proofing means for the organization. The problem of housekeeping an team working is particularly pertinent to set-up time reuctions an the elimination of errors. The poor housekeeping has resulte in the following problems: Operators an engineers are unable to quickly fin equipment such as tools, s, clamps, etc. Unuse an scrappe jigs an s are iscare in places which make them a safety hazar. Equipment breakown is accepte as inevitable. With respect to team working it was frequently observe that operators in the machine controlle cycle of component manufacturing, which involve 3 minutes of cutting time, i nothing to help their colleagues in setting up an ajacent machine. There are currently no incentives/rewar/appreciation systems in place for pursing set-up time reuctions an mistake proofing. This, couple with a lack of a team working ethic, means that the Factory is not fully utilizing the tents of their workforce. The Factory has an aequate training an eucation Programme, recognize by recent Investors in People awar. In the last financi year each person, on average, receive the equivent of six ays of training; however this training has not covere SMED an mistake proofing methoologies. IV. Conclusions In this stuy, SMED methoology is applie to prepare an optim stanar proceure for changeover operations on efine machine. Ergonomics an safety issues were so taken into consieration uring setups. Since an ergonomic workplace makes operations easier for the operators, simple however cruci changes are suggeste. Further stuies in the facility may inclue 5S an Kaizen stuies for intern setup. Alternative ways to shorten intern setups can be searche in etail. In orer to eliminate ajustment steps, tri an errors shoul be minimize. Settings must be use for changeover operations instea of ajustments. Therefore, a esign of experiments stuy can be one to etermine parameters of the machine. It shoul be kept in min that successful implementation of new prouction methos requires sustainability an permanent solutions an the key of sustainability is the stanarization of that optim solution. As a conclusion, it can be state that SMED single minute exchange of ie in other wors Quick Changeover is still a suitable metho not only for manufacturing improvement but so for equipment/ ie esign evelopment. References Références Referencias 1. Shingo, Singo, 1985, A Revolution in Manufacturing : the SMED System, Prouctivity Press, Cambrige, MA. Shingo, S. Zero Quity Control: Source Inspection an the Poka Yoke System, Prouctivity Press, Cambrige, MA. 2. S.Patel, P.Shaw an B.G.De, 21, Set-up time reuction an mistake proofing methos: A stuy of application in a sml factory Business Process Management Journ, vol No. 1, pp B.Kayis, S Kara, 27, Set-up Reuction (SUR) in Injection Moling Process- A Stuy in packing Inustry, 4 th Internation Conference an Exhibition on Design an Prouctivity of Machine an Dies / Mouls, Cesme, Turkey, 21-23/6/ Ali Allahveri & H.M. Soroush, 28, The significance of reucing setup times/setup costs European Journ of Operation Research 187, pp Subhashish Samaar, Craig A. Hill, 27, Controlling averse effect on work in process inventory while reucing machine setup time, European Journ of Operation Research 18, pp Jeffrey E. Schler b. Jatiner N.D. Gupta, Single machine scheuling with family setups to 7. Kuo-Lung Hou, 27, An EPQ moel with setup cost an process quity as functions of capit 19 Volume XII Issue V Version I ( A ) Glob Journ of Researches in Engineering 212 Glob Journs Inc. (US)

7 Prouctivity Enhancement by Reucing Setup SMED: Case stuy in the Automobile factory 2 Glob Journ of Researches in Engineering ( A ) Volume XII Issue V Version I expeniture, Applie Mathematic Moeling 31, pp Michele Ciavotta, Paolo Detti, Carlo Meloni, Marco Pranzo,28, A bi-objective coorination setup problem in a two-stage prouction system, European Journ of Operation Research 189 pp Dirk Van Goubergen, Henrik Van Laneghem, 199, A Quantitative Approach for Set-Up Reuction of Machine Lines, Prouction an Inventory Management Journ, 31(4): pp Dirk Van Goubergen, Henrik Van Laneghem, 1994, An Integrate Methoology for More Effective Set-up Reuction Prouction an Inventory Management Journ, 6 (2): pp Mehmet Cakmakci, 28, Process improvement: performance anysis of the setup time reuction- SMED in the automobile inustry Springer-Verlag Lonon Limite. 12. Dirk Van Goubergen, Henrik Van Laneghem, 22 Reucing Set-up s of Manufacturing Lines Internation Conference on Flexible Automation an Intelligent Manufacturing, Dresen, Germany. 13. Mehmet Cakmakci. Mahmut Kem Karasu, 26, Set-up time reuction process an integrate preetermine time system MTM-UAS: A stuy of application in a large size factory of automobile inustry Springer-Verlag Lonon Limite. 14. Dirk Van Goubergen, Henrik Van Laneghem, 2, An Integrate Methoology for More Effective Set-up Reuction, Proc. IIE Solutions, Clevelan (OH). 15. Joakim Storck, Bengt Linberg, 27, A Cost Moel for the Effect of Setup Reuction in Stainless Steel Strip Prouction, Sweish Prouction Symposium. 16. Kishna Rana, Ephrem Eyob,26, Incorporation of learning curves in Economic orer quantity ( EOQ) an Economic Prouction quantity ( EPQ) Scientific Journ of Aministrative evelopment Vol- 4, pp Kishna Rana, Ephrem Eyob Incorporation of learning curves in Economic orer quantity ( EOQ) an Economic Prouction quantity ( EPQ) Scientific Journ of Aministrative evelopment Vol- 4 26, pp Docki Saraswati, Ani Cakravastia an Abul Hakim Him, A Joint Economic Lot Sizing Moel with a Setup Reuction for a Single Supplier an a Single Buyer Proceeings of the 7th Asia Pacific Inustri Engineering an Management Systems Conference 26, 17-2 December 26, Bangkok, Thailan. 19. Lukas Richter, Jaroslav Kr Economic Orer Quantity Moel an its Utilization. University of Zilina. 2. Shu-Lu Hsu Setup Cost Reuction in the Lumpy Deman Prouction Quantity Moel with Discounting Information an Management Science Volume11, No 4, 2, pp Ana Sofia Alves Improving SMED in the Automotive Inustry: Case stuy POMS 2th Annu Conference Orlano, Flori U.S.A, May1 to May 4, Berna Ulutas An application of SMED Methoology, Worl Acaemy of Science, Engineering an Technology Turkey Glob Journs Inc. (US)

Set Up Change Time Optimization Using Single Minute Exchange of Die (SMED) Methodology

Set Up Change Time Optimization Using Single Minute Exchange of Die (SMED) Methodology International Journal of Research in Electronics ISSN : 2348-9065 (Online) Set Up Change Optimization Using Single Minute Exchange of Die (SMED) Methodology I Pankajkumar. J. Mistry, II Mukesh Desai I