an-najah national university faculty of engineering industrial engineering department project title:...
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An-najah National University
Faculty of EngineeringIndustrial Engineering Department
Project Title: SMED (Single Minute Exchange of Die)
System
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Supervisor Name: Eng. Tamer Haddad
Prepared by :Deyala Hanbali Nosayma SahbanAfnan Abu-Alhiega Reem Ismaeel
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Outline
Introduction Setup SMED
Description Extrusion Process Description Dies Description
Current die exchange Analysis Assessment of the SMED methodology in
NAPCO Recommendation
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SMED system
Single-Minute Exchange of Die is one of
the many lean production methods for
reducing waste in a manufacturing process.
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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.
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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.
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Case study
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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
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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.
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Setup
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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,
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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
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• 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
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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
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DescriptionDescription
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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.
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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.
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Aluminum Extrusion Process
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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
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Current Die
exchange analysis
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In current state
500 different dies
with an average of exchanging 13 dies
per day
with an average 8.98 minutes for each
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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
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TaskFlat die(sec)Hollow die(sec)
MinMaxStdAvgMinmaxStdAvg
Cut the last butt end and stop the machine and open die slide
6.35028.1205.31713.68210.35043.1108.5520.794
Remove the old die by the crane and put it on the floor
11.4277.05016.52936.67615.93079.22017.437.725
Place insert in the machine by the crane to support the die
14.5380.37014.34232.83615.430116.272844.692
Remove the crane to dies furnace
24.3050.7306.75331.1639.54288.34014.930.172
get the new die from furnace and place it in the machine
12.1373.55015.97840.63420.100111.6823.346.697
close die slide and turn on machine
11.1365.13012.96723.42016.06057.45010.928.184
Extrude the first profile and handle it by the gripper
29.07100.08021.08260.34340.380176.0644.191.229
Inspect the extruded profiles by the crane and the angle
125.0420.44083.245268.9775.030359.0373.7271.471
Total time233.9895.470507.72202.821031.2570.964
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flat die
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Assessment of the SMED
methodology in NAPCO
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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%
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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 EI I
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Setup ChecklistNo.QuestionsYesNO
1The die well cleaned
2The die assembled in the correct way
3Proper die in the furnace
4The die reach the specific temperature
5Availability of proper insert
6Availability of the crane beside the machine
7The operator ready to change the die
8The responsibility for everyone mineddeter
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Stage 2:Converting the internal setup to external setup
several types of waste can occur
NAPCO ProcedureSMED 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
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“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
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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
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Streamlining all aspects of the setup operation:
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Recommendation
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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%
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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
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4. Determine who is the responsible for exchanging the die and to identifying clear responsibilities for each worker
Recommendation
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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
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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
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The method of the work
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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
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