Reduction in Engine Change-Over Time Using SMED Methodology

In today’s world, customer demands comprise of a wide range of quality products delivered in a short span of time and also at a reasonable price. To meet these demands, manufacturers are constantly trying to reduce the cycle time of individual products as well as the changeover time between two different products. A lot of effort and money needs to be put in for reducing the cycle time of the products which is achieved through advanced costly technologies and rigorous quality measures. On the other hand, reducing the changeover time is an effective way in meeting the JIT philosophy without degrading the quality of the products. The SMED or ‘Single Minute Exchange of Dies’ methodology developed by Shigeo Shingo is an effective way in reducing the changeover time and has been verified through its application in a multinational engine manufacturing industry. In the following case study, proper implementation of the SMED methodology has been made and significant setup time reduction with minimum investment has been achieved. Further, the new methods have been standardized and sustained which has increased productivity ensuring safety and quality of the products.