Optimizing the changeover of packaging machine by implementing single minute exchange of dies in textile manufacturing industry

• Main Author: Rosli, Mohamad Muzammir
• Format: Thesis
• Language: English; English
• Published: 2016
• Subjects: T Technology (General); TS Manufactures
• Online Access: http://eprints.utem.edu.my/id/eprint/20546/1/Optimizing%20the%20changeover%20of%20packaging%20machine%20by%20implementing%20single%20minute%20exchange%20of%20dies%20in%20textile%20manufacturing%20industry.pdf; http://eprints.utem.edu.my/id/eprint/20546/2/Optimizing%20the%20changeover%20of%20packaging%20machine%20by%20implementing%20single%20minute%20exchange%20of%20dies%20in%20textile%20manufacturing%20industry.pdf; http://eprints.utem.edu.my/id/eprint/20546/; https://plh.utem.edu.my/cgi-bin/koha/opac-detail.pl?biblionumber=104923
• Institution: Universiti Teknikal Malaysia Melaka

Today, the majority of firms, particularly in the manufacturing domain, are espousing flexibility with regard to manufacturing an anay of products. The aim is to meet consumers'requirements so as to remain competitive and afloat in the industry. This can be done by ensuring a swift changeover of the machinery in such a way that the flexibility of response to demand stays unaffected. A textile firm in Melaka, Malaysia has adopted this approach. To achieve this objective, Single Minute Exchange of Dies (SMED) was deployed to enchance the changeover time of its packaging machine.It was noted that the key issue was the absence of lean thinking by workers, which caused much waste in the changeover process, and in turn the changeover time. By deploying SMED, some waste can be decreased or totally eradicated. The SMED framework involved determining the present changeover process, segregating internal and external tasks, converting maximum internal tasks into external ones, and streamlining all changeover tasks. It was observed that all tasks that are part of this procedure were accomplished internally. On analysis, it was ascertained that one of these tasks had the potential to be accomplished externally, and this task was preparation of new base and receiver. Few of the tasks in the changeover process were removed by enhancing the correlation between the operator and technician in charge of the machine. These tasks were changeover preparation, emptying pins from bowl feeder, putting new pins,and preparing for next run.A new jig was devised and fabricated,aiming at replacing the present jig which can only be utilised by one kind or size of packaging box. This jig intended to get rid of the need to prepare other base when various kinds or sizes of pins require to be packaged. To upgrade the improvements, other lean tools were recommended, including 5S and andon. 5S was recommended to enhance the task of preparing base and receiver by installing an indicator or label for quick identification by the technician. Andon was recommended to enhance the correlation between labourers and inform the technicians regarding the changeover. By means of all these enhancements, a new changeover process which is much easier and time saving was produced.It was observed that with the new process, the total changeover time consumed was 9.5 minutes as against 32.1 minutes for the original changeover time,indicating a saving of around 70 percent. To conclude, this study showed that SMED remains one of the most robust and effective tools which can be utilised to attain a swift changeover that is essential for this firm for making flexibility as one of its strong areas.