Single Minute Exchange of Dies as the Solution on Setup Processes Optimization by Decreasing Changeover Time, A Case Study in Automotive Part Industry

Abstract

Industrial competition nowadays demanding automotive manufacturers to increase productivity and organise lean production to meet all the targets. The rear axle manufacturer, one of the automotive industry in 2018, experienced production constraints that were unable to meet production targets. The Line Housing F as the object of this research had 9 machines that involved setup time for the changeover process out of 24 machines. The setup process was not being standardized, conducted manually and involved readjustment on the engine jig, which would, causes a long changeover time because the process was repeatedly carried out. This study aimed to optimize setup activities in order to reduce changeover time. The Single Minute Exchange of Dies (SMED) method was one of the applicable tools to reduce change over time, by changing the internal activities into external activities. In the final stage, SMED simplified the jig setting process by changing the jig design on the M16.3 machine and parallelizing the setup and process operations of the machine. The final results improved the 33% overall changeover time, from 58.36 to 39.22 minutes.