An-najah National University

Faculty of EngineeringIndustrial Engineering Department

Project Title: SMED (Single Minute Exchange of Die)

System

Supervisor Name: Eng. Tamer Haddad

Prepared by :Deyala Hanbali Nosayma SahbanAfnan Abu-Alhiega Reem Ismaeel

Outline

Introduction Setup SMED

Description Extrusion Process Description Dies Description

Current die exchange Analysis Assessment of the SMED methodology in

NAPCO Recommendation

SMED system

Single-Minute Exchange of Die is one of

the many lean production methods for

reducing waste in a manufacturing process.

Lean system

The lean approach aims to meet demand instantaneously, with perfect quality and minimum waste .

Waste : anything that doesn’t add value to the process or anything that doesn’t help create conformance to the customer specifications.

SMED system

Dies were the first improvement target and the reason SMED came to be, but the thinking carries over into many other areas.

SMED has to do with every kind of changeover setup, from high volume, low mix to mass production to the job shop's high mix, low volume manufacturing process.

Case study

Comparisons will be made between the current system in the factory and SMED system that is being studied in order to achieve the targeted goals which is reducing waste and cost, higher reliability and quality

The main objectives of our project:

Increased machine work rates from reduced setup times

Elimination of setup errors and elimination of trial runs

Improved quality from fully regulated operating conditions in advance.

Simplified housekeeping from fewer tools and better organization.

Lower expense of setups.

Setup

SMED

is a articular tool that avoids dead times

and reduces the setup operations; It was

developed for the first time inside

Toyota by Shigeo Shingo in 1955

(Shingo,

The big Idea of SMED

Changeover times can be

dramatically reduced in many

cases to less than 10 minutes,

Each element of the changeover

is analyzed to see if it can be

Eliminated, Moved, Simplified or

streamlined

• Defined as the elements or work that must be carried out while the machine or equipment is shut down

Internal setup

• defined as set-up elements which can take place while the machine is in operation or after the operation is completed

External setup

The main steps of SMED can be summarized as follows:

Step 1: Separating internal and external setup.

Step 2: Converting internal setup to external setup.

Step 3: Streamlining all aspects of the setup operation

DescriptionDescription

Extrusion process description

Extrusion is a process used to create objects of a fixed cross-sectional profile. A material is pushed or drawn through a die of the desired cross-section as shown in the figure . The two main advantages of this process are its ability to create very complex cross-sections and forms finished parts with an excellent surface finish.

The main steps of the extrusion process are shown below in the process flow chart below, from receiving the logs to moving the profiles to the storage or to the painting line.

Aluminum Extrusion Process

Dies Description

The extrusion die, itself, is a steel disk (normally H13) with an opening, the size and shape of the intended cross-section of the final extruded product, cut through it.

Dies are grouped as flat dies, which produces solid shapes, and hollow dies, which produces hollow or semi hollow shapes.

Flat dies Hollow dies

Current Die

exchange analysis

In current state

500 different dies

with an average of exchanging 13 dies

per day

with an average 8.98 minutes for each

Sample of calculation

13 changes * 8.98 min/change = 116.74 minutes (time wasted per day).

In order to know how many hours wasted per day: 116.74min*1hour/60min=1.95hour. 1.95hour * (700$/hour)day = 1365 $/day wasted cost during die

changeover per day. 1365$/day*12month/year*24day/month= 393,120$/year

TaskFlat die(sec)Hollow die(sec)

MinMaxStdAvgMinmaxStdAvg

Cut the last butt end and stop the machine and open die slide

6.35028.1205.31713.68210.35043.1108.5520.794

Remove the old die by the crane and put it on the floor

11.4277.05016.52936.67615.93079.22017.437.725

Place insert in the machine by the crane to support the die

14.5380.37014.34232.83615.430116.272844.692

Remove the crane to dies furnace

24.3050.7306.75331.1639.54288.34014.930.172

get the new die from furnace and place it in the machine

12.1373.55015.97840.63420.100111.6823.346.697

close die slide and turn on machine

11.1365.13012.96723.42016.06057.45010.928.184

Extrude the first profile and handle it by the gripper

29.07100.08021.08260.34340.380176.0644.191.229

Inspect the extruded profiles by the crane and the angle

125.0420.44083.245268.9775.030359.0373.7271.471

Total time233.9895.470507.72202.821031.2570.964

flat die

Assessment of the SMED

methodology in NAPCO

Stage 0(Internal and External setup):

Die

assembly

Transfer

the

Die to

Preheat

The die

Take

out the

old die

Insert

new

die

Test

the

new

setup

Clean

the old

die

Transfer

to

storage

0.328% 0.813% 56.879% 0.168% 0.197% 1.678% 39.612% 0.325%

Die

assembly

Transfer

the

Die to

Preheat

The die

Take

out the

old die

Insert

new

die

Test

the

new

setup

Clean

the old

die

Transfer

to

storage

Stage 1: Separating internal and

external setup:

E E E E E EI I

Setup ChecklistNo.QuestionsYesNO

1The die well cleaned

2The die assembled in the correct way

3Proper die in the furnace

4The die reach the specific temperature

5Availability of proper insert

6Availability of the crane beside the machine

7The operator ready to change the die

8The responsibility for everyone mineddeter

Stage 2:Converting the internal setup to external setup

several types of waste can occur

NAPCO ProcedureSMED evaluation

Finished Goods are

transported to storage or the

next batch of raw materials

are moved from storage into

the work station when the

machine is shut down

Select proper die before shut down

the machine.

Select proper insert before shut

down the machine

The old machine is transferred while

the machine is turn on. )

Acceptable

“Discretionary Time”

taken by operator

during internal set-up

time (when machine is

idle) to take breaks, eat,

talk.

No “Discretionary Time” taken by

operator during internal set-up time

No need to startup time because the

production is continuous .

Acceptable

Next job is not ready and

operator has to wait for

parts to come from the

supplying work center

Next job is always ready because

they use preheating system that

softened the billets prior to

extrusion.

Die storage have a clearly marked

and specific location. (Dies need to

always be returned to the same

location, in “production ready”

condition

Acceptable

Parts that are no longer

needed are transported to

the tool room while the

machine is turned off.

The old die transported to

the tool room after turn

on the machine

Acceptable

Start die heated after turn

off the machine

Also in preparation

NAPCO use preheating in

order to reduce the time

that taken for setup

Acceptable

Streamlining all aspects of the setup operation:

Recommendation

1. Add another crane

Shut down

the

machine

and open

die slide

Remove

the old die

Place

insert in

the

machine

Remove

the crane

to dies

furnace

get the

new die

Insert

new

die

close

die

slide

Inspect

the

extruded

profiles

0.328% 0.813% 56.879% 0.168% 0.197% 1.678% 39.612% 0.325%

Recommendation

2.Using alarm in the machine to indicate that the production plan for the current die is about to end to solve the availability problem of the operator

3 .Training the workers and motivated them to increase the productivity and loyalty for the company and to follow the instructions

4. Determine who is the responsible for exchanging the die and to identifying clear responsibilities for each worker

Recommendation

5.Use Automated Die Polishing system.

Inspection has the highest time during dies setup with an average 4.5 minutes as they inspect the first 8 meters of the profile to insure that it has a good quality

Use Automated Die Polishing system.

This computer control system enables close tolerances to be maintained and, because of its inherent flexibility, the process can be applied to a wide range of Extrusion dies

The method of the work

6. use double die slide system

where there is two slides to put the dies in, one for

the current die and the other for the new die without

the need to take out the old one which will reduce

the time and eliminate a lot of internal activities and

eventually reach to One-Touch Exchange of Die

(OTED),where the time became less than

100seconds