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Article
Publication date: 1 October 2018

Jagdeep Singh, Harwinder Singh and Inderdeep Singh

The purpose of this paper is to uncover the significance of SMED in manufacturing environments.

2196

Abstract

Purpose

The purpose of this paper is to uncover the significance of SMED in manufacturing environments.

Design/methodology/approach

The paper gives setup instructions and guidelines to prepare the standardized setup procedure without ignoring actual constraints in production environment. It uses a case study in a small-scale manufacturing unit of northern India to generate an integrated setup reduction approach, utilizing Single Minute Exchange of Die (SMED)-based industrial engineering tools to achieve faster setups. It describes the feasibility of quick changeovers in small enterprises based on an “SMED” approach. Finally, the paper carries out empirical analysis of the financial/non-financial benefits incurred from setup reductions.

Findings

Setup activities are a vital part of the production lead time of any product and so affect overall product cost. Industrial engineering techniques have been used to analyze the existing procedure of setups. A SMED approach can help eliminate unwanted activities, externalize the internal activities, if possible, and reduce them by simplification or standardization.

Originality/value

The paper demonstrates the practical application of SMED showing how it can bring real breakthroughs in reducing setup time in small-scale manufacturing.

Details

Benchmarking: An International Journal, vol. 25 no. 7
Type: Research Article
ISSN: 1463-5771

Keywords

Article
Publication date: 10 August 2018

Caner Ekincioğlu and Semra Boran

There can be activities that cannot reduce times by conventional single minute exchange of die (SMED) tools. In this case more advanced tools are needed. The purpose of this paper…

Abstract

Purpose

There can be activities that cannot reduce times by conventional single minute exchange of die (SMED) tools. In this case more advanced tools are needed. The purpose of this paper is to integrate the fuzzy Taguchi method into the SMED method in order to improve the setup time. The reason for using fuzzy logic is the subjective evaluation of factor’s levels assessment by experts. Subjective assessment contains a certain degree of uncertainty and is vagueness. The fuzzy Taguchi method provides to determining optimal setup time parameters in an activity of SMED. So it is possible to reduce time more than the conventional SMED method.

Design/methodology/approach

In this study, the SMED method and the fuzzy Taguchi method are used.

Findings

In this study, it has been shown that the setup time is reduced (from 196 to 75 min) and the optimum value can be given at the intermediate value by the fuzzy Taguchi method.

Originality/value

In this limited literature research, the authors have not found a study using the fuzzy Taguchi method in the SMED method.

Details

Journal of Enterprise Information Management, vol. 31 no. 6
Type: Research Article
ISSN: 1741-0398

Keywords

Article
Publication date: 19 March 2024

Rouhollah Khakpour, Ahmad Ebrahimi and Seyed-Mohammad Seyed-Hosseini

This paper recommends a method entitled “SMED 4.0” as a development of conventional single minute exchange of die (SMED) to avoid defect occurrence during production and improve…

Abstract

Purpose

This paper recommends a method entitled “SMED 4.0” as a development of conventional single minute exchange of die (SMED) to avoid defect occurrence during production and improve sustainability, besides reducing setup time.

Design/methodology/approach

The method builds upon an extensive literature review and in-depth explorative research in SMED and zero defect manufacturing (ZDM). SMED 4.0 incorporates an evolutionary stage that employs predict-prevent strategies using Industry 4.0 technologies including the Internet of Things (IoT) and machine learning (ML) algorithms.

Findings

It presents the applicability of the proposed approach in (1) identifying the triple bottom line (TBL) criteria, which are affected by defects; (2) predicting the time of defect occurrence if any; (3) preventing defective products by performing online setting on machines during production as needed; (4) maintaining the desired quality of the product during the production and (5) improving TBL sustainability in manufacturing processes.

Originality/value

The extended view of SMED 4.0 in this research, as well as its analytical approach, helps practitioners develop their SMED approaches in a more holistic way. The practical application of SMED 4.0 is illustrated by implementing it in a real-life manufacturing case.

Details

Journal of Manufacturing Technology Management, vol. ahead-of-print no. ahead-of-print
Type: Research Article
ISSN: 1741-038X

Keywords

Article
Publication date: 31 January 2023

Luciana Paula Reis, June Marques Fernandes, Sergio Evangelista Silva and Carlos Augusto de Carvalho Andreosi

This article aims to introduce a guide to improving hospital bed setup by combining lean technical practices (LTPs), such as kaizen and value stream mapping (VSM) and lean social…

257

Abstract

Purpose

This article aims to introduce a guide to improving hospital bed setup by combining lean technical practices (LTPs), such as kaizen and value stream mapping (VSM) and lean social practices (LSPs), such as employee empowerment.

Design/methodology/approach

Action research approach was employed to analyze the process of reconfiguration of bed setup management in a Brazilian public hospital.

Findings

The study introduces three contributions: (1) presents the use of VSM focused specifically on bed setup, while the current literature presents studies mainly focused on patient flow management, (2) combines the use of LSPs and LTPs in the context of bed management, expanding current studies that are focused either on mathematical models or on social and human aspects of work, (3) introduces a practical guide based on six steps that combine LSPs and LSPs to improve bed setup management.

Research limitations/implications

The research focused on the analysis of patient beds. Surgical beds, delivery, emergency care and intensive care unit (ICU) were not considered in this study. In addition, the process indicators analyzed after the implementation of the improvements did not contemplate the moment of the COVID-19 pandemic. Finally, this research focused on the implementation of the improvement in the context of only one Brazilian public hospital.

Practical implications

The combined use of LSPs and LTPs can generate considerable gains in bed setup efficiency and consequently increase the capacity of a hospital to admit new patients, without the ampliation of the physical space and workforce.

Social implications

The improvement of bed setup has an important social character, whereas it can generate important social benefits such as the improvement of the admission service to patients, reducing the waiting time, reducing hospitalization costs and improving the hospital capacity without additional physical resources. All these results are crucial for populations, their countries and regions.

Originality/value

While the current literature on bed management is more focused on formal models or pure human and social perspectives, this article brings these two perspectives together in a single, holistic framework. As a result, this article points out that the complex bed management problem can be efficiently solved by combining LSPs and LTPs to present theoretical and practical contributions to the important social problem of hospital bed management.

Details

Journal of Health Organization and Management, vol. 37 no. 2
Type: Research Article
ISSN: 1477-7266

Keywords

Article
Publication date: 18 March 2024

Syed Mithun Ali, Muhammad Najmul Haque, Md. Rayhan Sarker, Jayakrishna Kandasamy and Ilias Vlachos

Bangladesh's ready-made garment (RMG) industry plays a vital role in the economic growth of this country. As the global trend in the fashion market has introduced a high-mix…

Abstract

Purpose

Bangladesh's ready-made garment (RMG) industry plays a vital role in the economic growth of this country. As the global trend in the fashion market has introduced a high-mix, low-volume ordering style, manufacturers are facing an increased number of changeovers in their production systems. However, most of the Bangladeshi RMG manufacturers are not yet ready to respond to such small orders and to improve the flexibility of their production systems. Consequently, the industry is falling behind in global market competition. Thus, this study aims to advance the current performance of RMG manufacturing operations to respond to the fast-fashion industry's challenges effectively using quick changeover.

Design/methodology/approach

In this study, a Single-Minute Exchange of Dies (SMED) is applied to attain quick changeover following the best practices of lean manufacturing.

Findings

This study examined the performance of the SMED technique to reduce changeover time in two case organisations. The changeover time was reduced by 70.76% from 434.56 min to 127.08 min and 42.12% from 2,664 min to 1,542 min for the case organisations, respectively. The results of this study show that companies require improved changeover times to address the demand for high-mix, low-volume orders.

Originality/value

This study will certainly guide practitioners of the RMG industry to adopt SMED to reduce changeover time to meet small batch production.

Details

Benchmarking: An International Journal, vol. ahead-of-print no. ahead-of-print
Type: Research Article
ISSN: 1463-5771

Keywords

Article
Publication date: 26 February 2021

Choon Hee Ong, You Ying Koo, Owee Kowang Tan and Chin Fei Goh

This paper aims to examine the role of rational culture in the relationship between lean manufacturing practices and operational productivity in the machinery and equipment…

Abstract

Purpose

This paper aims to examine the role of rational culture in the relationship between lean manufacturing practices and operational productivity in the machinery and equipment industry.

Design/methodology/approach

This study uses a cross-sectional quantitative approach to conduct the research. Using an online survey questionnaire, 118 responses were collected. SPSS was used to assess validity, reliability and hypothesis testing of the study variables. Hierarchical regression analysis was employed to investigate the moderating effects of rational culture.

Findings

The study results reveal that quick setup and quality control were significantly related to operational productivity. Rational culture was a significant quasi-moderator.

Practical implications

This study highlights the importance of quick setup and quality control for machinery and equipment firms to gain higher operational productivity. Rational culture could be used to drive the firms toward greater achievements in this regard.

Originality/value

The use of rational culture as a quasi-moderator in the relationship between lean manufacturing practices and operational productivity is unprecedented. This study offers new findings by introducing the role of rational culture to enhance the effects of lean manufacturing practices on operational productivity.

Details

Journal of Manufacturing Technology Management, vol. 32 no. 5
Type: Research Article
ISSN: 1741-038X

Keywords

Article
Publication date: 1 November 2002

Jiaqin Yang and Richard H. Deane

The importance of reducing product lotsizes in converting traditional job shops into just‐in‐time (JIT) type manufacturing systems has been addressed in the literature. This paper…

2138

Abstract

The importance of reducing product lotsizes in converting traditional job shops into just‐in‐time (JIT) type manufacturing systems has been addressed in the literature. This paper presents a lotsize reduction model for closed stochastic production systems. The model is formulated based on an M/G/c queuing lotsize model. Product lotsize choice is related to all major components of job flow time: waiting time in queue, batch processing time, batch moving time, and finished goods warehousing time. The research is motivated by the fact that an optimal lotsize solution that minimizes only average job waiting time in the shop may not be optimal when the effects of job batch processing time, batch moving time, and batch warehousing time are also considered. There is no general closed form solution to the model due to the complexity of its nonlinear formulation. Based on the unique properties of the model, heuristic solution procedures are developed. The research demonstrates opportunities for shop managers to significantly reduce product lotsizes while minimizing total operating cost.

Details

Integrated Manufacturing Systems, vol. 13 no. 7
Type: Research Article
ISSN: 0957-6061

Keywords

Article
Publication date: 7 March 2023

Wen Zhang, Guohui Chen and Qiguo Gong

This paper aims to systematically understand the development of rapid setup, quantitatively analyze the landscape and reveal new trends and challenges.

Abstract

Purpose

This paper aims to systematically understand the development of rapid setup, quantitatively analyze the landscape and reveal new trends and challenges.

Design/methodology/approach

Based on 192 literature studies (1987–2021) collected from Scopus and Google Scholar, the papers are classified by: publication time and source; research type and data analysis of papers; pattern of authorship and country; sector-wise focus of the paper; improvement method used in the setup. And CiteSpace is used to analyze the cooccurrence and timeline of keywords.

Findings

There has been substantial progress in the past 35 years, including the rapid growth in the number of papers, the expansion in different disciplines, the participation of developing countries, the application in the service industry and the significant impact of setup on cost. And there are still some deficiencies.

Research limitations/implications

There is concern that Google Scholar lacks the quality control needed for its use as a bibliometric tool. Future work is encouraged to conduct an in-depth discussion on high-quality papers.

Practical implications

In small batch production, rapid setup is increasingly essential. Clarifying the research focus and main improvement methods is of great significance for enterprises to meet the changing market needs.

Originality/value

To the best of the authors’ knowledge, this study is the first literature review on rapid setup. It is decided to consider a detailed set of data for better introspection and trace the history reflections and the research future in setup time.

Details

International Journal of Lean Six Sigma, vol. 14 no. 7
Type: Research Article
ISSN: 2040-4166

Keywords

Article
Publication date: 1 May 2003

Wei‐Shing Chen and Chiuh‐Cheng Chyu

This paper considers the decision problem for a minimum setup strategy of a production system arising in the assembly of printed circuit boards of different types, using a…

Abstract

This paper considers the decision problem for a minimum setup strategy of a production system arising in the assembly of printed circuit boards of different types, using a placement machine with multi‐slot feeders. We formulate the problem as a binary linear programming model, and propose a heuristic procedure to find the solution that consists of a board‐assembly sequence, an associated component loading and unloading strategy and a feeder‐assignment plan within reasonable computational effort. Computational results from solving the simulated problem instances by using the heuristic method and the mathematical model are provided and compared. The proposed heuristic procedure can be incorporated into the PCB scheduling optimization software to decrease cycle times and increase overall assembly throughput in a high‐mix, low‐volume PCB manufacturing environment.

Details

Integrated Manufacturing Systems, vol. 14 no. 3
Type: Research Article
ISSN: 0957-6061

Keywords

Article
Publication date: 1 August 1993

Subhashish Samaddar and Lance Heiko

Waste is defined as anything other than the minimum amount ofresources which are absolutely essential to add value to the product.Resources include equipment, parts, materials…

Abstract

Waste is defined as anything other than the minimum amount of resources which are absolutely essential to add value to the product. Resources include equipment, parts, materials, space, energy, worker′s time, and so on. Explores six types of waste which are relevant to all types of operations. Presents ways to eliminate all six. Uses examples relevant to both manufacturing and services. Provides summary implications. Concludes that a systematic and continuous identification and elimination of waste should be used to increase efficiency, improve productivity and enhance competitiveness.

Details

Industrial Management & Data Systems, vol. 93 no. 8
Type: Research Article
ISSN: 0263-5577

Keywords

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