Rationalization of retooling process with use of SMED and simulation tools

Abstract

In the paper, the problem of limited flexibility of manufacturing companies is discussed. The problem consists in the necessity to manufacture in big lots with respect to long-lasting retooling of machines. This is illustrated on the example of an automotive enterprise. Implementation process of the SMED method (Single-Minute Exchange of Die) is presented. Potential improvements were verified with use of simulation models of basic and auxiliary processes, prepared in the program iGrafx Process for Six Sigma. Combination of the SMED method with simulation tools made it possible to develop a new, more effective standard of retooling. To estimate yearly profit, calculations were made with use of a spreadsheet.