Optimizing The Changeover Of Pressure Die Casting Machine By Implementing Single Minute Exchange Of Die

Embok Resa, Mohammad Afif (2019) Optimizing The Changeover Of Pressure Die Casting Machine By Implementing Single Minute Exchange Of Die. Project Report. UTeM, Melaka, Malaysia. (Submitted)

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Abstract

These days, most of the manufacturing industry are on the verge to produce products at high variety at a low cost with shorter delivery time due to the increasing competition in the sector. The issue can be countered by endorsing a quick changeover to the industry to achieve flexible and lean manufacturing. A door hardware company in Melaka, Malaysia has implemented Single Minutes Exchange of Die (SMED) in order to reduce the changeover time of its Pressure Die Casting machine. The objectives of this study are to study the ongoing changeover process, to propose new operating procedure of the changeover process and then to validate the new operating procedure of the changeover process. This study was only focused on the Pressure Die Casting 1 machine. Root cause determined by conducting time study, video recording, direct observations and interview session. By implementing SMED, the waste of the changeover process managed to be eliminated. The current changeover has been analysed, internal and external tasks were identified and separated by using checklist, performing function checks and transportation of mould improvement. Conversion of internal to external tasks been made by applying ECRS method and implementation of 5S. All aspects in changeover process were streamlined in terms of parallel operations between the operator and the setter, usage of functional clamp, improvement of fixtures and hoses line connections. Therefore, new operating procedure was developed and implemented which is easier and quicker. Validation of new operating procedure resulting in changeover time reduction of 94 minutes; from 201 minutes to 107 minutes which is equivalent to 46.77% changeover time reduction. Clearly, this study proved that Single Minutes Exchange of Die (SMED) is one of the most powerful LM tools for quick changeover.

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