The Single Minute Exchange of Die (SMED) methodology is a Lean Production tool applied to reduce setup times and improve production flexibility. Multiple studies have demonstrated its effectiveness across several industries. This study was developed in an industrial environment in the cutting section of a company that produces electrical wiring harnesses for the automotive industry. The main objective was to apply the SMED methodology to the cutting machines to reduce their setup times. The main problems identified were the lack of space between machines, inadequate organization of workstations, lack of standardization of the setup process and repeated setups. The improvement proposals drawn up consisted of removing two cutting machines to allow the quick-change system to be implemented, developing a trolley for the tool magazine and developing a support table and terminal holder. The implementation of the quick-change system resulted in a 255 s reduction in setup time, which, after a year of work, has the potential to increase production by 831 h, making it possible to cut 668854 additional wires. This potential increase in productivity translates into a monetary gain of €65280. In addition, with the labor savings, this improvement represents a total annual gain of €74155 for the company. The supply trolley increased the number of materials transported per journey, which means an increase of 200%. The other actions implemented were essentially focused on improving the organization of the workstations and reducing the number of movements made by workers.

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Application of SMED Methodology in the Cutting Segment of an International Cable Manufacturing Company

  • Diana Ferreira,
  • Ana C. Ferreira,
  • Ângela Silva

摘要

The Single Minute Exchange of Die (SMED) methodology is a Lean Production tool applied to reduce setup times and improve production flexibility. Multiple studies have demonstrated its effectiveness across several industries. This study was developed in an industrial environment in the cutting section of a company that produces electrical wiring harnesses for the automotive industry. The main objective was to apply the SMED methodology to the cutting machines to reduce their setup times. The main problems identified were the lack of space between machines, inadequate organization of workstations, lack of standardization of the setup process and repeated setups. The improvement proposals drawn up consisted of removing two cutting machines to allow the quick-change system to be implemented, developing a trolley for the tool magazine and developing a support table and terminal holder. The implementation of the quick-change system resulted in a 255 s reduction in setup time, which, after a year of work, has the potential to increase production by 831 h, making it possible to cut 668854 additional wires. This potential increase in productivity translates into a monetary gain of €65280. In addition, with the labor savings, this improvement represents a total annual gain of €74155 for the company. The supply trolley increased the number of materials transported per journey, which means an increase of 200%. The other actions implemented were essentially focused on improving the organization of the workstations and reducing the number of movements made by workers.