Benefits from a SMED Application in a Punching Machine
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.
[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.
[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.
@article{"International Journal of Mechanical, Industrial and Aerospace Sciences:65476", author = "Eric Costa and Sara Bragança and Rui Sousa and Anabela Alves", title = "Benefits from a SMED Application in a Punching Machine", 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. ", volume = "7", number = "5", pages = "940-7", }
