An application of the SMED methodology in an electric power controls company

Detalhes bibliográficos
Autor(a) principal: Ribeiro, Domingos
Data de Publicação: 2011
Outros Autores: Braga, Fernando, Sousa, Rui M., Silva, Sílvio Carmo
Tipo de documento: Artigo
Idioma: eng
Título da fonte: Repositório Científico de Acesso Aberto de Portugal (Repositórios Cientìficos)
Texto Completo: http://hdl.handle.net/1822/15892
Resumo: Lean production is a strategy for high competiveness in manufacturing. The capability for economical manufacture in small batch sizes is an essential requirement for achieving lean production. This facilitates mixed production of several kinds of products to match varying product demand and can have a major impact in reducing inventories. An obvious requirement for this is the high frequency of equipment setups or product changeovers. This will not be attractive unless set-up times and costs can be reduced to competitive levels. The application of SMED can achieve this. SMED is a well-established methodology involving a set of techniques, methods and guidelines to achieve fast product changeovers at machines. This paper describes the application of SMED in the production process of plastic and metal components required for the assembly of several types of circuit breakers. The work was carried out during a short period of a few months under a master thesis project. Several important SMED strategies and solutions were implemented and evaluated in terms of their impact on productivity and on other manufacturing performance measures. Three specific machines were involved: a punch-bending machine, a punch press and an injection moulding machine. An important contribution was made by introducing innovative and simple solutions such as adapting tools and normalizing changeover operations. Most of the achieved results exceeded the initial expectations. Beyond the purely technical and economic benefits of SMED, better workstations’ ergonomic conditions were also attained. Besides the usual quantification of setup time reduction, other indicators were calculated, namely: work-in- process (WIP), annual setup cost and distance travelled by operators during the changeover process. Reductions of setup time varying from 59% to 90% were achieved. WIP of metal components was reduced from 17.05 to 7.74 days reducing more than 50% on the corresponding costs. A more impressive reduction on WIP was obtained for plastic parts, actually from 5 to 1.09 days of work corresponding to a WIP cost reduction of over 80%. The distance travelled by operators during the changeover process was dramatically reduced too: typically a reduction from 300 m to 10 m and less. The total annual cost savings projection, in this small area of parts production, is near 20,000 €. Although large benefits were obtained from the study, scope for further improvement still exists. In fact the objective of product changeover times below 10 minutes aimed by SMED was not achieved in one case.
id RCAP_edf539ac200f294b0665fd5f180171df
oai_identifier_str oai:repositorium.sdum.uminho.pt:1822/15892
network_acronym_str RCAP
network_name_str Repositório Científico de Acesso Aberto de Portugal (Repositórios Cientìficos)
repository_id_str 7160
spelling An application of the SMED methodology in an electric power controls companySMEDLean manufacturingMachine setupMass customizationQuick changeoverLean production is a strategy for high competiveness in manufacturing. The capability for economical manufacture in small batch sizes is an essential requirement for achieving lean production. This facilitates mixed production of several kinds of products to match varying product demand and can have a major impact in reducing inventories. An obvious requirement for this is the high frequency of equipment setups or product changeovers. This will not be attractive unless set-up times and costs can be reduced to competitive levels. The application of SMED can achieve this. SMED is a well-established methodology involving a set of techniques, methods and guidelines to achieve fast product changeovers at machines. This paper describes the application of SMED in the production process of plastic and metal components required for the assembly of several types of circuit breakers. The work was carried out during a short period of a few months under a master thesis project. Several important SMED strategies and solutions were implemented and evaluated in terms of their impact on productivity and on other manufacturing performance measures. Three specific machines were involved: a punch-bending machine, a punch press and an injection moulding machine. An important contribution was made by introducing innovative and simple solutions such as adapting tools and normalizing changeover operations. Most of the achieved results exceeded the initial expectations. Beyond the purely technical and economic benefits of SMED, better workstations’ ergonomic conditions were also attained. Besides the usual quantification of setup time reduction, other indicators were calculated, namely: work-in- process (WIP), annual setup cost and distance travelled by operators during the changeover process. Reductions of setup time varying from 59% to 90% were achieved. WIP of metal components was reduced from 17.05 to 7.74 days reducing more than 50% on the corresponding costs. A more impressive reduction on WIP was obtained for plastic parts, actually from 5 to 1.09 days of work corresponding to a WIP cost reduction of over 80%. The distance travelled by operators during the changeover process was dramatically reduced too: typically a reduction from 300 m to 10 m and less. The total annual cost savings projection, in this small area of parts production, is near 20,000 €. Although large benefits were obtained from the study, scope for further improvement still exists. In fact the objective of product changeover times below 10 minutes aimed by SMED was not achieved in one case.Universidade do MinhoFundação para a Ciência e a Tecnologia (FCT)Institutul de Cercetara-Dezvoltare Pentru Mecatronica Si Tehnical Masurarii (INCDTM)Universidade do MinhoRibeiro, DomingosBraga, FernandoSousa, Rui M.Silva, Sílvio Carmo20112011-01-01T00:00:00Zinfo:eu-repo/semantics/publishedVersioninfo:eu-repo/semantics/articleapplication/pdfapplication/pdfhttp://hdl.handle.net/1822/15892eng1584-5982http://www.cefin.ro/editura/revista/index.php?pag=show_articol&id_articol=371&lang=eninfo:eu-repo/semantics/openAccessreponame:Repositório Científico de Acesso Aberto de Portugal (Repositórios Cientìficos)instname:Agência para a Sociedade do Conhecimento (UMIC) - FCT - Sociedade da Informaçãoinstacron:RCAAP2023-07-21T12:29:14Zoai:repositorium.sdum.uminho.pt:1822/15892Portal AgregadorONGhttps://www.rcaap.pt/oai/openaireopendoar:71602024-03-19T19:24:12.295574Repositório Científico de Acesso Aberto de Portugal (Repositórios Cientìficos) - Agência para a Sociedade do Conhecimento (UMIC) - FCT - Sociedade da Informaçãofalse
dc.title.none.fl_str_mv An application of the SMED methodology in an electric power controls company
title An application of the SMED methodology in an electric power controls company
spellingShingle An application of the SMED methodology in an electric power controls company
Ribeiro, Domingos
SMED
Lean manufacturing
Machine setup
Mass customization
Quick changeover
title_short An application of the SMED methodology in an electric power controls company
title_full An application of the SMED methodology in an electric power controls company
title_fullStr An application of the SMED methodology in an electric power controls company
title_full_unstemmed An application of the SMED methodology in an electric power controls company
title_sort An application of the SMED methodology in an electric power controls company
author Ribeiro, Domingos
author_facet Ribeiro, Domingos
Braga, Fernando
Sousa, Rui M.
Silva, Sílvio Carmo
author_role author
author2 Braga, Fernando
Sousa, Rui M.
Silva, Sílvio Carmo
author2_role author
author
author
dc.contributor.none.fl_str_mv Universidade do Minho
dc.contributor.author.fl_str_mv Ribeiro, Domingos
Braga, Fernando
Sousa, Rui M.
Silva, Sílvio Carmo
dc.subject.por.fl_str_mv SMED
Lean manufacturing
Machine setup
Mass customization
Quick changeover
topic SMED
Lean manufacturing
Machine setup
Mass customization
Quick changeover
description Lean production is a strategy for high competiveness in manufacturing. The capability for economical manufacture in small batch sizes is an essential requirement for achieving lean production. This facilitates mixed production of several kinds of products to match varying product demand and can have a major impact in reducing inventories. An obvious requirement for this is the high frequency of equipment setups or product changeovers. This will not be attractive unless set-up times and costs can be reduced to competitive levels. The application of SMED can achieve this. SMED is a well-established methodology involving a set of techniques, methods and guidelines to achieve fast product changeovers at machines. This paper describes the application of SMED in the production process of plastic and metal components required for the assembly of several types of circuit breakers. The work was carried out during a short period of a few months under a master thesis project. Several important SMED strategies and solutions were implemented and evaluated in terms of their impact on productivity and on other manufacturing performance measures. Three specific machines were involved: a punch-bending machine, a punch press and an injection moulding machine. An important contribution was made by introducing innovative and simple solutions such as adapting tools and normalizing changeover operations. Most of the achieved results exceeded the initial expectations. Beyond the purely technical and economic benefits of SMED, better workstations’ ergonomic conditions were also attained. Besides the usual quantification of setup time reduction, other indicators were calculated, namely: work-in- process (WIP), annual setup cost and distance travelled by operators during the changeover process. Reductions of setup time varying from 59% to 90% were achieved. WIP of metal components was reduced from 17.05 to 7.74 days reducing more than 50% on the corresponding costs. A more impressive reduction on WIP was obtained for plastic parts, actually from 5 to 1.09 days of work corresponding to a WIP cost reduction of over 80%. The distance travelled by operators during the changeover process was dramatically reduced too: typically a reduction from 300 m to 10 m and less. The total annual cost savings projection, in this small area of parts production, is near 20,000 €. Although large benefits were obtained from the study, scope for further improvement still exists. In fact the objective of product changeover times below 10 minutes aimed by SMED was not achieved in one case.
publishDate 2011
dc.date.none.fl_str_mv 2011
2011-01-01T00:00:00Z
dc.type.status.fl_str_mv info:eu-repo/semantics/publishedVersion
dc.type.driver.fl_str_mv info:eu-repo/semantics/article
format article
status_str publishedVersion
dc.identifier.uri.fl_str_mv http://hdl.handle.net/1822/15892
url http://hdl.handle.net/1822/15892
dc.language.iso.fl_str_mv eng
language eng
dc.relation.none.fl_str_mv 1584-5982
http://www.cefin.ro/editura/revista/index.php?pag=show_articol&id_articol=371&lang=en
dc.rights.driver.fl_str_mv info:eu-repo/semantics/openAccess
eu_rights_str_mv openAccess
dc.format.none.fl_str_mv application/pdf
application/pdf
dc.publisher.none.fl_str_mv Institutul de Cercetara-Dezvoltare Pentru Mecatronica Si Tehnical Masurarii (INCDTM)
publisher.none.fl_str_mv Institutul de Cercetara-Dezvoltare Pentru Mecatronica Si Tehnical Masurarii (INCDTM)
dc.source.none.fl_str_mv reponame:Repositório Científico de Acesso Aberto de Portugal (Repositórios Cientìficos)
instname:Agência para a Sociedade do Conhecimento (UMIC) - FCT - Sociedade da Informação
instacron:RCAAP
instname_str Agência para a Sociedade do Conhecimento (UMIC) - FCT - Sociedade da Informação
instacron_str RCAAP
institution RCAAP
reponame_str Repositório Científico de Acesso Aberto de Portugal (Repositórios Cientìficos)
collection Repositório Científico de Acesso Aberto de Portugal (Repositórios Cientìficos)
repository.name.fl_str_mv Repositório Científico de Acesso Aberto de Portugal (Repositórios Cientìficos) - Agência para a Sociedade do Conhecimento (UMIC) - FCT - Sociedade da Informação
repository.mail.fl_str_mv
_version_ 1799132720050208768