PowerPoint Presentation

Final Year Project PresentationEnhancement of Productivity By SMED

GROUP MEMBERS

Group LeaderMuhammad Husnain Siddiqi Muhammad AhsanMuhammad Asad Ayyub Muhammad Asim AslamMuhammad Mairaj Saleem Project Supervisor Eng. Rano Khan Wassan

12/22/2016Department of Industrial Engineering and Management2

Overview12/22/20163

ProductivityIts not just doing more. Its aboutCreating more impact with less work INTRODUCTION

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SMED (Single-Minute Exchange of Dies) is a system for dramatically reducing the time it takes to complete equipment changeovers. The name Single-Minute Exchange of Dies comes from the goal of reducing changeover times to the single digits (i.e. less than 10 minutes).

Set up time: The time passed between the completion of the last product of the old series and the completion of the first good product of the new series.Change over: The process of switching from the production of one product or part number to another in a machine or a series of linked machines by changing parts, dies, molds or fixtures.

INTRODUCTION12/22/2016Department of Industrial Engineering and Management5

In SMED, changeovers are made up of steps that are termed elements. There are two types of elements:Internal Elements (elements that must be completed while the equipment is stopped)External Elements (elements that can be completed while the equipment is running).Real life example:The most famous application of Shigeo Shingo's SMED thatmost people have seen is that of changing a tire.INTRODUCTION12/22/2016Department of Industrial Engineering and Management6

In order to save valuable time changing tires on the car, the team carries out all external events while the driver is racing

Every team member knows his specific job and carries it out along with the other team members

Formula one Pit Stop - SMED in Action

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This study was conducted in Yunus Textile Mill. The study focused on reduction of changeover time based on the SMED methodology. We used this methodology in Singing & De-sizing, bleaching, mercerizing and printing department to reduce unnecessary time consumed by changeover activitiesLIMITATIONS OF STUDYPotential reduction in efficiency when adding new member who doesnt fully understand role.Costly when adding too many members to changeover process.Potential limitation of work space when adding too many member.

SCOPE OF STUDY 12/22/2016Department of Industrial Engineering and Management8

12/22/2016Department of Industrial Engineering and Management9Yunus Textile Mills Limited (YTM) is a vertically integrated textile mill located in Karachi, Pakistan.The company, with annual production capacity of 100 Million metersYTM also provides its customers design and distribution services with offices based in USA, France, Spain, United Kingdom and Canada.At present YTM supplies directly to majority of leading retailers of USA and Europe and is producing products for various private and retail brands.

INTRODUCTION OF YUNUS TEXTILES MILLS

LITERATURE REVIEWAuthor / YearTitle of PaperOutcomes Jonalee D. Bajpai/2014SMED in Garment Manufacturing Industry. Case study to reduce change over time. Style Change over time can be greatly reduced by application of SMED methodology with minimum financial implication.Pablo Guzmn Ferrads/ 2013Improving changeover time: a tailored SMED approach for welding cells The validation of the method resulted in 33% reduction of the changeover time of the welding cellVipan Kumar, Amit Bajaj/ 2012The Implementation of Single Minute Exchange of Die with 5S in Machining Processes for reduction of Setup TimeReduction in Setup time by eliminating no value adding.Ana Sofia Alves et.al/ 2009Single Minute Exchange of Dies: Literature ReviewTop management support increase the potential of SMED and SEMD can be applied in any industryCakmakci/ 2008Performance analysis of the setup time reduction-smed in the automobile industrySMED is still a suitable method not only for manufacturing improvement but also for equipment/die design development.

REDUCE THE CHANGEOVER TIME TO AVOID STARTUP LOSS

Why YTM need SMED Technique ?YTM is one of the largest exporter of Pakistan so they are facing great challenge from customer to deliver their product on time.

Product Customization has increased, thereby increasing the number of parts in a product family.

Quantities and complex design the production line setup has shrunk to such level that sometimes a unit might need to produce multiple orders in a single day.

There must be some technique to reduce the changeover time to avoid startup loss

PROBLEM STATMENT12/22/2016Department of Industrial Engineering and Management11

Our main focus on 4 areas in processing department:Singe &de-seizeBleaching.MercerizingPrinting rotaries.

TARGETED AREAS12/22/2016Department of Industrial Engineering and Management12

MAIN OBJECTIVESTo reduce the change over time using SMED.

SUB-OBJECTIVESTo provide SOP for change over processTo develop work culture according to JD (Job Description).Lower manufacturing costImproved responsiveness to customer demandOBJECTIVES 12/22/2016Department of Industrial Engineering and Management13

According to Shingo (1985), the main benefits of the SMED application are presented below: Setup time reductionReduction of time spent with fine tuning Fewer errors during change-overs Product quality improvementIncreased safety Increase of production flexibility Rationalization of tools

ADVANTAGES12/22/2016Department of Industrial Engineering and Management14

METHODOLOGY12/22/2016Department of Industrial Engineering and Management15

SINGING AND DE-SIZINGMajor problemsLong changeoverBatcher availabilityMachine stoppage due to maintenanceSuggestions Installation of j-scaryTPM (Total Productive Maintenance)

RESULT AND DISCUSSION12/22/2016Department of Industrial Engineering and Management16

12/22/2016Department of Industrial Engineering and Management17Average Changeover Data Comparison of SINGE AND DE-SIZE

BLEACHINGMajor ProblemsBatcher availability Maintenance Fresh chemical chargingSuggestionsLogistic departmentIntercom systemPredictive maintenanceFailure Mode & Effect Analysis (FMEA).Risk Matrix Add-on Based

RESULT AND DISCUSSION12/22/2016Department of Industrial Engineering and Management18

12/22/2016Department of Industrial Engineering and Management19AVERAGE CHANGEOVER DATA COMPARISON OF BLEACHING

MERCERIZINGMajor ProblemsWater draining ProblemElectrical worker waitingSuggestionsopening base Integration of electric switch in machine control panel

Result and Discussion12/22/2016Department of Industrial Engineering and Management20

12/22/2016Department of Industrial Engineering and Management21Average CHANGEOVER DATA COMPARISON OF MERCERIZING

PRINTINGMajor ProblemsLong changeoverSuggestionsLeveling holders are fixed on Rotary 1 & 2 like Rotary 3Proper placement of squeegee stand Proper maintenance of squeegee , holder, latto, Rods.Avoid reusing of squeegees.Integration of timer which records duration of changeover time.Changeover team and proper training.Monthly rewards for fastest changeover group.

Result and Discussion12/22/2016Department of Industrial Engineering and Management22

12/22/2016Department of Industrial Engineering and Management23AVERAGE CHANGEOVER DATA COMPARISON OF PRINTING

12/22/2016Department of Industrial Engineering and Management24PIE-CHART SHOWING TIME CONSUMED BY CHANGEOVER ACTIVITY

12/22/2016Department of Industrial Engineering and Management25SHINGO, S. (1985). A Revolution in Manufacturing: the SMED System. Productivity Press, Cambridge, MA.Jonalee D. Bajpai, SMED (Single-Minute Exchange of Die) methodology in Garment manufacturing Industry: Case study in reducing Style Change over Time, 2014Pablo Guzmn Ferrads, Konstantinos Salonitis, Improving changeover time: a tailored SMED approach for welding cells, 2013Vipan Kumar, Amit Bajaj, The Implementation of Single Minute Exchange of Die with 5S in Machining Processes for reduction of Setup Time, Volume: 2 Issue: 2Ana Sofia Alves, Improving SMED in the Automotive Industry: A case study.Cakmakci M, Process Improvement SMED in the automobile industry, 2009.

REFERENCES

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