Changeover time improvement of pressure die casting machine by single minute exchange of die implementation

• Main Author: Embok Resa, Mohammad Afif
• Format: Thesis
• Language: English; English
• Published: 2020
• Subjects: T Technology (General); TS Manufactures
• Online Access: http://eprints.utem.edu.my/id/eprint/25352/; https://plh.utem.edu.my/cgi-bin/koha/opac-detail.pl?biblionumber=119162

Globally, the manufacturing sector has undergone a turbulent period due to the growing in the competition to the existing market. Therefore, companies should improve their productivity by implementing Quick Changeover to cater the issues. With that, a door hardware company in Melaka, Malaysia has implemented Single Minutes Exchange of Die (SMED) to reduce the changeover time of its Pressure Die Casting 2 machine. The objectives of this study were to study the existing changeover process, to propose new Standard Operating Procedure (SOP) by streamlining the steps of the existing changeover process and designing quick coupling hoses, and then to validate the new Standard Operating Procedure (SOP) of the changeover process. This study was only attentive on the Pressure Die Casting 2 machine. The complications were identified by using 6-steps of Problem-Solving Method. The wastes of the changeover process were eliminated by implementing SMED which consists of Classification Phase, Separation Phase, Conversion Phase and streamlining all aspects. The internal and external tasks of the changeover process were identified then separated by using a checklist. Some of the internal tasks have been converted to external tasks by execution of pre-preparations of tools. Radical improvements comprise quick coupling hoses, marking at the crane, organize the unused hoses and the improvements of hoses line connections have contributed to the reduction of changeover time. After slight adjustment during SMED implementation, Task 1 (setter) has been eliminated as it was considered as the external task meanwhile Task 17 (setter) has been shifted to Task 8 (operator). As a result, there were 16 tasks done by the setter and 8 tasks done by the operator. After the implementation of SMED, the changeover time reduced as much as 25 minutes from 117 minutes to 92 minutes which is equivalent to 21.37% therefore achieved the initial target of 20% reduction. It is proven very clearly that SMED methodology able to reduce the time of changeover process in Pressure Die Casting 2 machine.