Skip to main content
SpringerLink
Log in

A novel framework for single-minute exchange of die (SMED) assisted by lean tools

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

Nowadays, the survival and success of companies depend on improving on-time delivery and cost reduction. To reach this target, it is necessary to get improvements, standardization, and controlling of the manufacturing systems. Therefore, the objective of this scientific work is to perform a case study, based on the implementation of new single-minute exchange of die (SMED) framework in an oil and gas company. This novel framework was developed based on a practical application of strategies such as improvements by ECRS (eliminate, combine, reduce, and simplify), standardized work (SW), and OEE (overall equipment effectiveness) control applied to the production processes. The findings achieved in this work showed setup time was improved by 91.6%, it moved from 1 h 44 min 56 s (6,296 s) to 8 min 52 s (532 s), and OEE increase 44.6%. And, the setup activities were standardized. Besides, on every workpiece manufactured, its setup time was measured and compared against to the target achieved. So, the novel framework developed has potential to provide competitiveness’ strategies to different branches of the industry.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7

Similar content being viewed by others

Data availability

All information, figures, and tables are in the manuscript. It will not be necessary to provide other data and materials.

References

  1. Slack N (2013) Brandon-Jones, A., and Johnston, R. Operations management, 7th ed. Pearson, Edinburgh, UK

  2. Shingo S (1985) A revolution in manufacturing. In: The SMED system. Productivity Press, Cambridge, MA

  3. Silva IB, Godinho Filho M (2019) Single-minute exchange of die (SMED): a state-of-the-art literature review. Int J Adv Manuf Technol 102:4289–4307

    Article  Google Scholar 

  4. Pacheco DAJ, Heidrich GDG (2021) Revitalising the setup reduction activities in operations management, Production Planning & Control.https://doi.org/10.1080/09537287.2021.1964881

  5. Moreira AC, Pais GCS, (2011) Single minute exchange of die. A case study implementation. J Technol Management and Innov 6(1):129–146

  6. Ulutas B (2011) An application of SMED methodology. International Scholarly and Scientific Research & Innovation 5(7):100–103

    Google Scholar 

  7. Lozano J, Saenz-Díez J, Martínez E, Blanco J (2017) Methodology to improve machine changeover performance on food industry based on SMED. Int J Adv Manuf Technol 90:3607–3618

    Article  Google Scholar 

  8. Ahmad R, Soberi MSF (2018) Changeover process improvement based on modified SMED method and other process improvement tools application: an improvement project of 5-axis CNC machine operation in advanced composite manufacturing industry. Int J Adv Manuf Technol 94:433–450

    Article  Google Scholar 

  9. Sindhuja D, Mohandas G, Madhumathi P (2012) Redesigning of horn assembly line using ECRS principles. International Journal of Engineering and Innovative Technology (IJEIT) 1(3):214–217

    Google Scholar 

  10. Womack JP, Jones DT, Roos D (1990) The machine that changed the world. Rawson Associates, New York

    Google Scholar 

  11. Liker JK (2004) The Toyota way: 14 management principles from the world’s greatest manufacturer. McGraw-Hill, New York

    Google Scholar 

  12. Chakravorty SS, Shah AD (2012) Lean six sigma (LSS): an implementation experience. European J Industrial Eng 6(1)

  13. Mann DW Creating a lean culture: tools to sustain lean conversions. New York: Productivity Press

  14. Dal Forno AJ, Pereira FA, Forcellini FA, Kipper LK (2014) Value stream mapping: a study about the problems and challenges found in the literature from the past 15 years about application of lean tools. Int J Adv Manuf Technol. https://doi.org/10.1007/s00170-014-5712-z

    Article  Google Scholar 

  15. Azizi A, Manoharan T (2015) Designing a future value stream mapping to reduce lead time using SMED a study. Procedia Manuf 2:153–158

    Article  Google Scholar 

  16. Seth D, Seth N, Dhariwal P (2017) Application of value stream mapping (VSM) for lean and cycle time reduction in complex production environments: a case study. Production Planning & Control 28(5):398–419

    Article  Google Scholar 

  17. Osada JGAP (2007) Interaction and connections among the 5S, the SMED and poka-yoke techniques in continued improvement processes. Re-creaciones 139–148

  18. Bevilacqua M, Ciarapica FE, De Sanctis I, Mazzuto G, Paciarotti CA (2015) Changeover time reduction through an integration of lean practices: a case study from pharmaceutical sector. Assem Autom 35(1):22–34

    Article  Google Scholar 

  19. Drew W (2016) Process implementation through 5S laying foundation for lean, Productivity Press

  20. Omogbaia O, Salonitisa K (2017) The implementation of 5S lean tool using system dynamics approach. Procedia CIRP 60:380–385

    Article  Google Scholar 

  21. Carnerud D, Jaca C, Bäckström I (2018) Kaizen and continuous improvement – trends and patterns over 30 years. The TQM Journal 30(4):371–390

    Article  Google Scholar 

  22. Saurin TA, Ribeiro JLD, Vidor G (2012) A framework for assessing poka-yoke devices. Journal of manufacturing system 31:358–356

    Article  Google Scholar 

  23. Oliveira J, Sá JC, Fernandes A (2017) Continuous improvement through lean tools: an application in a mechanical company. Procedia Manuf 13:1082–1089

    Article  Google Scholar 

  24. Mor RS, Singh BA, S, Sachdeva A, (2019) Productivity gains through standardization-of-work in a manufacturing company. J Manuf Technol Manag 30(6):899–919

    Article  Google Scholar 

  25. Culley SJ, Owen GW, Mileham AR, McIntosh RI (2003) Sustaining changeover improvement. Proc Inst Mech Eng B J Eng Manuf 17(10):1455–1470

    Article  Google Scholar 

  26. Reik MP, Mcintosh RI, Culley SJ, Mileham AR, Owen GW (2006a) A formal design for changeover methodology. Part 1: methodology and case study. Proc Inst Mech Eng B J Eng Manuf 220(8):1225–1235

  27. Reik MP, Mcintosh RI, Culley SJ, Mileham AR, Owen GW (2006b) A formal design for changeover methodology. Part 2: methodology and case study. Proc Inst Mech Eng B J Eng Manuf 220(8):1237–1247

  28. Cakmakci M (2009) Process improvement: performance analysis of the setup time reduction-SMED in the automobile industry. Int J Adv Manuf Technol 411:68–179

    Google Scholar 

  29. Braglia M, Frosolini M, Gallo M (2017) SMED enhanced 5-whys analysis to improve set-up reduction programs: the SWAN approach. Int J Adv Manuf Technol 90(5–8):1845–1855

    Article  Google Scholar 

  30. Rosa C, Silva FJG, Pinto Ferreira L, Campilho R (2017) SMED methodology: the reduction of setup times for steel wire-rope assembly lines in the automotive industry. Procedia Manufacturing 13:1034–1042

    Article  Google Scholar 

  31. Allahverdi A, Soroush HM (2008) The significance of reducing setup times/setup costs. Eur J Oper Res 187(3):978–984

    Article  Google Scholar 

  32. Mackelprang AW, Nair A (2010) Relationship between just-in-time manufacturing practices and performance: a meta-analytic investigation. J Oper Manag 28(4):283–302

    Article  Google Scholar 

  33. Das B, Venkatadri U, Paney P (2014) Applying lean manufacturing system to improving productivity of air conditioning coil manufacturing. Int J Adv Manuf Technol 71:307–323

    Article  Google Scholar 

  34. Burawat P (2019) Productivity improvement of carton manufacturing industry by implementation of lean six sigma, ECRS, work study, and 5S: a case study of ABC Co. J Environ Treat Tech 7(4):785–793

    Google Scholar 

  35. Suhardi B, Anisa N, Laksono PW (2019) Minimizing waste using lean manufacturing and ECRS principle in Indonesian furniture industry. Cogent Engineering 6(1):1–13

    Google Scholar 

  36. Nguyen V, Nguyen N, Schumacher B, Tran T (2020) Practical application of plan–do–check–act cycle for quality improvement of sustainable packaging: a case study. Appl. Sci. 10, 6332. https://doi.org/10.3390/app10186332

  37. Xue Q (2019) Research on single minute exchanging die (SMED) based on lean production, Master’s degree thesis, Departament of Mechanical & Aerospace Engineering. Politecnico di Torino

  38. Yin RK (2003) Case study research: design and methods. Thousand Oaks, CA: SAGE

  39. Martins M, Godina R, Pimentel C, Silva FJG, Matias JCO (2018) A practical study of SMED to electro-beam machining in automotive industry. Procedia Manufacturing 17:647–654

    Article  Google Scholar 

  40. Maalouf MM, Zaduminska M (2019) A case study of VSM and SMED in the food processing industry. Management and Production Engineering Review 10(2):60–68

    Google Scholar 

  41. Ibrahim MA, Mohamad E, Arzmi MH, Rahman MAA, Saptari A, Shighatullah AS, Sulaiman MA, Ali MAM (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

    Article  Google Scholar 

  42. Mansor MA Ismail AR Yasin MRM Halim A (2015) A framework for measuring the effect of changeover time to overall equipment effectiveness. Int Congress on Natural Sci Eng 798–806

  43. Basri AQ Mohamed NMZN (2017) The study of extended single minute exchange of die method in 1200 tonnage tandem press line for operation improvement. CIE47 Proceedings 1–7

  44. Tamas P (2017) Application of a simulation investigational method for efficiency improvement method. Academic Journal of Manufacturing Engineering 15(2):23–30

    Google Scholar 

  45. Mohamed BAQ, Yasir NMZN, Fazi KASHM, Fudzin HM, AF, (2018) The validation of productivity on the changeover activity at the automotive stamping press line by comparing the embedded SMED framework versus SMED approach: a witness simulation case study. IOP Conference Series: materials Science and Engineering. https://doi.org/10.1088/1757-899X/469/1/012005

    Article  Google Scholar 

  46. McIntosh R, Owen G, Culley S, Mileham T (2007) Changeover improvement: reinterpreting Shingo’s “SMED” methodology (2007). IEEE Transations on Engineering Management 54(1):98–111

    Article  Google Scholar 

  47. Hasabe A, Hakde A, Khandagle A, Surve K (2019) Single minute exchange of dies (SMED) concept, International Research Journal of. Eng Technol 06(04):4665–4669

    Google Scholar 

  48. Soberi MSF Idris NI Ahmad A Muhamad N Hussain MI (2015) Setup time reduction for 5-axis composite material’s trimming machine by a new framework of SMED integrated with ECSC concept. Int Symposium on Adv Ergonomics & Safety 1–9

  49. Suky NSA, Bakar EA, Ansari EI, Akhtar MN (2020) Single minute exchange die approach setup time in labelling printing company. Journal of Engineering Science 16(2):35–56

    Article  Google Scholar 

  50. Braglia M, Frosolini M, Gallo M (2016) Enhancing SMED: changeover out of machine evaluation technique to implement the duplication strategy. Production Planning & Control 27(4):328–342

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Department of Manufacturing and Materials Engineering, School of Mechanical Engineering, Campinas State University, Campinas, SP, Brazil

    Roberto Giani Pattaro Junior, Ricardo Henrique Inácio & Amauri Hassui

  2. Department of Mechanical Engineering, Sao Carlos School of Engineering, University of Sao Paulo, Sao Carlos, SP, Brazil

    Iris Bento da Silva

  3. Department of Mechanical Engineering, Federal University of Sao Carlos, Sao Carlos, SP, Brazil

    Gustavo Franco Barbosa

Authors
  1. Roberto Giani Pattaro Junior
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Ricardo Henrique Inácio
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Iris Bento da Silva
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Amauri Hassui
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Gustavo Franco Barbosa
    View author publications

    You can also search for this author in PubMed Google Scholar

Contributions

All authors contributed to the construction of the paper.

Corresponding author

Correspondence to Iris Bento da Silva.

Ethics declarations

Ethics approval

The authors declare that the article was constructed respecting all ethical conditions of publication.

Consent to participate

All authors participated in the preparation of the article. In this way, the authors allow their names to be in the article.

Consent for publication

Authors allow publication.

Conflict of interests

The authors declare no competing interests.

Additional information

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Junior, R.G.P., Inácio, R.H., da Silva, I.B. et al. A novel framework for single-minute exchange of die (SMED) assisted by lean tools. Int J Adv Manuf Technol 119, 6469–6487 (2022). https://doi.org/10.1007/s00170-021-08534-w

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-021-08534-w

Keywords

Search

Navigation