Setup time reduction of snap fastener machine by implementing single minute exchange of die

Mat Adam, Nur Syuhada (2017) Setup time reduction of snap fastener machine by implementing single minute exchange of die. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

Nowadays, majority of companies, especially in manufacturing industry, are bounded to produce variety of products at a low cost and shorter delivery time. This can be carried out by ensuring a rapid changeover of the machinery in such a way that the flexibility of response to demand stays unaffected. A needlework and sewing company in Melaka, Malaysia has adopted Single Minute Exchange of Die (SMED) to shorten the changeover time of its snap fastener machine. It was noted that the problem in the company was poor lean thinking by the workers, which resulted in waste in changeover process, and changeover time. By using SMED, current changeover process was observed, internal and external activities were separated, internal activities were converted into external activities, and all changeover activities were streamlined. One of the changeover activities had the potential to be performed externally, and i.e. preparation of new mould / die. Some of the changeover activities were cancelled out by adding more workers and enhancing the correlation between operator and technician in charge of changeover. These activities were preparation for the changeover, removing the brass strips from the machine, setting the position of the brass strip and preparation for next run. A new standard was developed and implemented, aiming at standardizing the block types which can only be used by one type of cutter. This cutter is intended to get rid of the need to make or design the new cutter from the plate when the cutter is worn-off. To enhance the effectiveness of the improvements, other lean tools were recommended, including andon. Andon was recommended to enhance the correlation between the workers and inform the technicians about the changeover. A new changeover process which is much easier and time saving was created. With the new process, it was observed that the total changeover time was 38 minutes compared to 306 minutes with the current changeover time, (87 percent reduction). This study showed that SMED remains one of the most simple and effective tool which can be used to attain a rapid changeover that is essential for this company.

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