APPLICATION OF SMED METHOD TO REDUCE THE SETUP TIME

Abstract

Lean Production System aims to meet the customer demand without any imperfection not only in the shortest time and in small batches but also by consuming less resource. It is the fundamental priority to shorten the duration of setup activities, which carried out from the end of the previous production of a batch to the beginning of the next the production. From this point of view, Single Minute Exchange of Die (SMED), which is one of the lean production techniques, is an effective method to reduce losses of time during machine setup periods. SMED approach, which enables a faster setup, has been implemented on injection machines of a company, which is manufacturing testing, and assembly parts in automotive and electrical sector. The current case was analyzed and improvements were made with SMED and 5S techniques. As a result, both durations (before and after the implementation of two techniques mentioned above) were measured and it has been observed that setup durations were reduced from 65.30 minutes to 23.62 minutes. 

Keywords

• Toyota Production System,Exchange of Die,5S,Internal Setups,External Setups

HAZIRLIK SÜRESİNİN AZALTILMASINDA SMED YÖNTEMİ UYGULAMASI

Abstract

Yalın üretim sistemi, müşteri talebini az kaynak kullanımı ile en kısa sürede, küçük partiler halinde ve hatasız olarak karşılamayı amaçlamaktadır. Bir partinin üretiminin bitiminden diğer partinin üretiminin başlangıcına kadar gerçekleştirilen faaliyetlerin sürelerinin toplamından oluşan hazırlık zamanının kısaltılması bu amacın gerçekleşmesi için gereklidir. Bu doğrultuda yalın üretim tekniklerinden biri olan SMED (Single Minute Exchange of Die: tekli dakikalarda kalıp değişimi) makine hazırlık zamanlarındaki kayıpları azaltmaya yönelik kullanılan etkin bir yöntemdir. Bu çalışmada daha hızlı iş değişimini mümkün kılan SMED yaklaşımı, otomotiv ve elektrik sektörlerinde test ve montaj parçaları üreten bir firmada enjeksiyon makinelerinde uygulanmıştır. Mevcut durum analiz edilmiş, SMED yaklaşımı ve 5S ile iyileştirmeler yapılmıştır. İyileştirme öncesi ve sonrası hazırlık zamanları ölçülmüş ve 65,30 dakikalık süre, 23,62 dakikaya kadar düşürülmüştür. 

Keywords

• Toyota Üretim Sistemi,Kalıp Değişimi,5S,iç değiştirme

References

1. Allahverdi, A., & Soroush, H. M. (2008). The significance of reducing setup times/setup costs. European Journal of Operational Research, 187(3), 978-984.
2. Alves, A. S., & Tenera, A. (2009). Improving SMED in the Automotive Industry: A case study. In POMS 20th Annual Conference Orlando, Florid USA, May1 to May (Vol. 4).
3. Bajpai, J. D. (2014, December). Smed (single-minute exchange of die) methodology in garment manufacturing industry: Case study in reducing style change over time. In Proceedings of the 5th International & 26th All India Manufacturing Technology, Design and Research Conference (AIMTDR 2014), Guwahati, India (pp. 12-14).
4. Borges Lopes, R., Freitas, F., & Sousa, I. (2015). Application of lean manufacturing tools in the food and beverage industries. Journal of technology management & innovation, 10(3), 120-130.
5. Cakmakci, M., & Karasu, M. K. (2007). Set-up time reduction process and integrated predetermined time system MTM-UAS: A study of application in a large size company of automobile industry. The International Journal of Advanced Manufacturing Technology, 33(3-4), 334-344.
6. Cakmakci, M. (2009). Process improvement: performance analysis of the setup time reduction-SMED in the automobile industry. The International Journal of Advanced Manufacturing Technology, 41(1-2), 168-179.
7. Çelik, H., & Taşkın, K. (2019), Smed Uygulamasının Ayar Süresine ve Birim Maliyete Etkisi: Kabuk Soyma Parlak Çelik Üretim Hattı Uygulaması. İşletme Bilimi Dergisi, 7(1), 77-103.
8. Ekincioğlu, C., & Boran, S. (2018). SMED methodology based on fuzzy Taguchi method. Journal of Enterprise Information Management, 31(6), 867-878.

9. Faccio, M., Cohen, Y., Bevilacqua, M., Ciarapica, F. E., De Sanctis, I., Mazzuto, G., & Paciarotti, C. (2015). A Changeover Time Reduction through an integration of lean practices: a case study from pharmaceutical sector. Assembly Automation.
10. Hodge, G. L., Goforth Ross, K., Joines, J. A., & Thoney, K. (2011). Adapting lean manufacturing principles to the textile industry. Production Planning & Control, 22(3), 237-247.
11. Ibrahim, M. A., Mohamad, E., Arzmi, M. H., Rahman, M. A. A., Saptari, A., Shibghatullah, A. S., ... & Ali, M. A. M. (2015). Enhancing efficiency of die exchange process through single minute of exchanging die at a textile manufacturing company in Malaysia. J Appl Sci, 15(3), 456-464.
12. Jebaraj Benjamin, S., Murugaiah, U., & Srikamaladevi Marathamuthu, M. (2013). The use of SMED to eliminate small stops in a manufacturing firm. Journal of Manufacturing Technology Management, 24(5), 792-807.
13. Karasu, M. K., Cakmakci, M., Cakiroglu, M. B., Ayva, E., & Demirel-Ortabas, N. (2014). Improvement of changeover times via Taguchi empowered SMED/case study on injection molding production. Measurement, 47, 741-748.
14. Kemalbay, V. (2012). Tekli Dakikalarda Kalıp Değiştirme Zeki Karar Destek Sistemi Ve Tekstil Sektöründe Uygulaması(Doctoral dissertation, Fen Bilimleri Enstitüsü).
15. Lozano, J., Saenz-Díez, J. C., Martínez, E., Jiménez, E., & Blanco, J. (2019). Centerline-SMED integration for machine changeovers improvement in food industry. Production Planning & Control, 30(9), 764-778.
16. Moreira, A.C., & Campos Silva Pais, G. (2011). Single minute exchange of die: a case study implementation. Journal of technology management & innovation, 6(1), 129-146.
17. Moxham, C., & Greatbanks, R. (2001). Prerequisites for the implementation of the SMED methodology: A study in a textile processing environment. International Journal of Quality & Reliability Management, 18(4), 404-414.
18. Shingo, S. (1985). A revolution in manufacturing: the SMED system. Productivity Press.
19. Shingo, S., (1989). A study of the Toyota production system: From an Industrial Engineering Viewpoint. Çev. Dillon, A. P. CRC Press.
20. Tanık, M. (2013). Kalıp Ayar Sürelerinin Smed Metodolojisi İle İyileştirilmesi: Bir Yalın Altı Sigma Uygulaması. Muğla Üniversitesi Sosyal Bilimler Enstitüsü Dergisi, (25), 117-140
21. Ulutas, B. (2011). An application of SMED Methodology. World academy of science, engineering and technology, 79, 101.
22. Van Goubergen, D., & Van Landeghem, H. (2002). Rules for integrating fast changeover capabilities into new equipment design. Robotics and computer-integrated manufacturing, 18(3-4), 205-214.