Optimizing the Changeover of Pressure Die Casting Machine by Implementing Single Minute Exchange of Die

抄録

Today, much of the manufacturing industry is on the verge of producing a high variety of products with lower costs and shorter delivery times, in response to growing competition. This development can be advanced by promoting quick changeover practices such that companies can achieve lean and flexible manufacturing capability. To his end, an established door hardware firm in Melaka, Malaysia has applied Single Minutes Exchange of Die (SMED) so as to shorten changeover times in the operation of its Pressure Die Casting machine. The goals of this review are to examine the firm’s on-going changeover processes, to propose newer operational procedures for these changeover processes, followed by validation of the new procedures. This review only focused on the firm’s Pressure Die Casting 1 machine. The root causes were determined by performing time studies, video recordings, direct observation, and interview sessions. By implementing SMED, wastage in changeover processes could be reduced. Existing changeover procedures were analysed, while internal and external tasks were recognised and separated through the use of checklists, performing-function checks, and transport of mould improvements. The conversion of internal tasks to external tasks was accomplished through implementation of the ECRS and 5S approaches. Every aspect of the changeover processes was streamlined with regards to parallel operations among setters and operators, usage of the functional clamp, and improvements in fixture and hose line connections. Consequently, newer operating procedures were developed and applied for easier and faster operation. Validation of these newer procedures established a changeover time reduction of some 201 minutes down to 107 minutes, or 94 minutes in all, which equates to a 46.77% reduction in changeover time. Clearly, this review showed that SMED comprised one of the more powerful LM techniques for optimising process changeover.