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Mold Change Setup Time Reduction for Vacuum Forming Machine
1* 2
E-mail: [email protected]*
Nantachai Kantanantha1* Norawat Luangtong2
1,2Department of Industrial Engineering, Faculty of Engineering, Kasetsart University, Bangkok E-mail: [email protected]*
SMED Why-Why 3
41.04
SMED
Abstract
The purpose of this study is to reduce the mold change setup time for vacuum forming machine of the
refrigerator manufacturer. The study begins from determining the mold change procedure in each step to determine the causes of the delay. Next the work study is performed using the time chart and flow
process chart, and the activities are classified as internal and external setups according to the SMED (Single Minute Exchange of Die) Principle. The causes of the delay are then determined by Why-Why
Analysis. This results in three improvement ways including planning the mold storage to reduce the mold
moving time, preparing the tools before working to reduce the tool searching time during the operation, and re-ordering the steps of operations and re-assigning the duties of operators to balance the workload.
As a result, the mold change setup time decreases 41.04 percent.
Keywords: Mold Change, Work Study, Work Improvement, SMED Principle
1.
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Door Liner Vacuum Forming
(Acrylonitrite Butadiene Styrene, ABS)
(Door Liner) (Vacuum Forming Machine)
60 70
2.
2.1 (Work Study)
[1]
Li [2]
45.6%
2.2 (Flow Process Chart)
[1]
(Flow Diagram)
[3] (Turnaround Time) [4 ]
[5]
2.3 Why-Why (Why-Why Analysis)
Why-Why
(Toyota Production
System, TPS) [6] � � � �
5
5-Why Why-Why
Lakshman [7] Why-Why
2.4 SMED (Single Minute Exchange of
Die Principle)
SMED
(Internal Setup)
(External Setup)
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[8]
SMED
26.6
11.2
3.
3.1
Door Liner Vacuum Forming
ABS Door Liner
Door Liner Door Liner
3
1
2
3
3.2
8
3
68.86
3.3
3
1
1
3
85
1
(%) (%)
1 100 0
2 52 48
3 15 85
3.4
2
1
3
2
( )
( )
( )
( )
1 17 16 1 34
2 5 7 0 12
3 4 1 0 5
3.5
2 SMED
3
3
( )
( )
1 12 22
2 1 11
3 3 2
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3 1
2
3
1 3 2
3.6 Why-Why
3 Why-why
4
4 5
1.
2.
3.
4.
ECRS ECRS
(Eliminate) (Combine) (Rearrange) (Simplify)
4 Why-Why
What Why Why Why Why
1. - -
2. - -
-
-
-
3. - C-Clamp - - C-Clamp
4. -
-
-
-
-
-
-
-
5. -
-
- -
