An-najah National University Faculty of Engineering Industrial Engineering Department Project Title: SMED (Single Minute Exchange of Die) System Supervisor Name: Eng. Tamer Haddad Prepared by : Deyala Hanbali Nosayma Sahban Afnan 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 Description 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 Task Flat die(sec) Hollow die(sec) Min Max Std Avg Min max Std Avg Cut the last butt end and stop the machine and open die slide 6.350 28.120 5.317 13.682 10.350 43.110 8.55 20.794 Remove the old die by the crane and put it on the floor 11.42 77.050 16.529 36.676 15.930 79.220 17.4 37.725 Place insert in the machine by the crane to support the die 14.53 80.370 14.342 32.836 15.430 116.27 28 44.692 Remove the crane to dies furnace 24.30 50.730 6.753 31.163 9.542 88.340 14.9 30.172 get the new die from furnace and place it in the machine 12.13 73.550 15.978 40.634 20.100 111.68 23.3 46.697 close die slide and turn on machine 11.13 65.130 12.967 23.420 16.060 57.450 10.9 28.184 Extrude the first profile and handle it by the gripper 29.07 100.080 21.082 60.343 40.380 176.06 44.1 91.229 Inspect the extruded profiles by the crane and the angle 125.0 420.440 83.245 268.97 75.030 359.03 73.7 271.471 Total time 233.9 895.470 507.72 202.82 1031.2 570.964 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 E I I Setup Checklist No. Questions Yes NO 1 The die well cleaned 2 The die assembled in the correct way 3 Proper die in the furnace 4 The die reach the specific temperature 5 Availability of proper insert 6 Availability of the crane beside the machine 7 The operator ready to change the die 8 The responsibility for everyone mineddeter Stage 2: Converting the internal setup to external setup several types of waste can occur NAPCO Procedure SMED 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