Optimizing changeover of packaging machine by implementing single minute exchange of die (SMED) at textile manufacturing company

Anwar, Nur Batrisya (2021) Optimizing changeover of packaging machine by implementing single minute exchange of die (SMED) at textile manufacturing company. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

One of Lean Manufacturing's tools is the Single Minute Exchange of Die (SMED) which minimises preparation time and time of machinery changeover. The purpose of the SMED approach is to convert as much of the improvements externally. External setup takes place while the machine is running. It also attempts to simplified and optimise the preparation of the machine. Extracted from the objective of reducing the time of changeover in one digit, the term "Single-Minute Exchange of Die" means any operation or process must be less than 10 minutes. The textile manufacturing company produces the concept of sewing and apparel products such as seam ripper, pearl pins, and so on. Nevertheless, this automatic packaging machines achieved lower daily output compared to manual packaging output due to high time consumption during conversion to other items. This high preparation time can be replaced by more product production processes. Therefore, the goal of this project is to reduce the changeover time of the packaging machine in order to increase the production of products compared to manual packaging along with proposing several solutions. The approach continues with observations, semi-structured interviews, brainstorming and focus groups to gather information on packaging machines and way to reduce the changeover time. Together is collecting time taken for each activity from the changeover process that will be recorded using a video camera. Once the process is analysed, a list of new changeover processes has been obtained as well as problems been discovered in the current machine setup process. For this reason, few analyses constructed to know in detail what is the cause of delay in an activity. Hence, solution has been recommended to solve the issues which has achieved 65.7% reduction in the changeover time. It has been demonstrated that the SMED technique is capable of significantly reducing the setup time of equipment, in this case the packaging machine.

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