Improvement of production line flexibility through rapid changeover via time reduction of internal activities

Abdul Hakim, Nur Raihana (2019) Improvement of production line flexibility through rapid changeover via time reduction of internal activities. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

Nowadays, the manufacturing sectors are in the process to increase their performance to increase productivity because there are so many challenges from competitors in the same sectors, especially in the food industries. The purpose of this study is to understand the Single Minute Exchange of Dies (SMED) factor occurs in the production line according to the first objective of this study. SMED method is a set of techniques that make it possible to perform the setup of equipment and changeover operations for less than ten minutes. It can be applied by changing the internal activities to become external activities. The method is applied by reducing the internal activities that cause the changeover time getting longer. The second objective is to practice the SMED in the production line of manufacturing industries in order to improve the production line flexibility through the rapid changeover. Besides the paper also summarizes all the major issues that affected productivity in the SMED method. There a few methods that are done in order to complete this study. The first method is to identify the problem and objective of the study. After that, the data collection is done by observation and also the data from the company itself. An interview is also done by interviewing the operator to know the exact process that occurs in the production line. The data collection then will be analyzed by using Fishbone Diagram and Why Why Analysis. In this study, the Fishbone Diagram tool is used to find the root cause of the problem while Why Why Analysis is used to find the solution of the root cause. The result only can be done after the data is being analyzed in order to find the solution for problems that occur in the food industries. Thus, there are a few proposed improvements is proposed for this study. The first suggested improvement is to create a Standard Operating Procedure (SOP) for the changeover. The second proposed improvement is to redesign new mixture tanks that were flexible to move and last but not least is to proposed a changeover training schedule. However, there is some limitation for this research as the data collected is not completed because there is no production and sometimes the workers do not record the data. This study is useful for manufacturing managers and a company willing to increase flexibility and at the same time can reduce the changeover time within their available resources without compromise the machine efficient and without using high cost. This study also describes what is believed to be the first thing to study that explicitly examines the problem faced in achieving higher flexibility and at the same time can increase production. In conclusion, this study had provided a better understanding of the implementation of the SMED method by reducing the internal activities that cause the changeover time getting higher. In addition, the last objective to propose the SMED method for enhancing productivity is achieved.

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