An integrated SMED-fuzzy FMEA model for reducing setup time
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An integrated SMED-fuzzy FMEA model for reducing setup time Kübra Yazıcı1
· Seda Hatice Gökler2
· Semra Boran2
Received: 30 January 2020 / Accepted: 18 September 2020 © Springer Science+Business Media, LLC, part of Springer Nature 2020
Abstract Today, the companies apply lean or customized production methods, which enable the production of different kinds of products in small quantities, to meet different customer demands. But, the increase in the product variety leads to an increase in the number of setups and thus production time. The companies aim to reduce the setup time by improving activities and by eliminating the problems causing extending setup time. Single minute exchange of die (SMED) method is the most common setup method that makes it possible to perform equipment setup operations in fewer than 10 min, i.e. several minutes expressed by a single digit. It is possible to further reduce setup times by integrating quality tools and methods into the SMED method. In this study, it is developed a novel SMED model that integrating the traditional SMED and fuzzy failure modes and effects analysis (fuzzy-FMEA) methods. Fuzzy FMEA method is used to prevent problems causing further extending setup time on setup activities. A new operation worksheet, “Setup Observation and Analysis Form” that leads the analyst in during the investigation of the machine and its set-up process, is also designed. The new approach is applied to set up a plastic injection mold for a pen manufacturing company. The setup time is reduced from 71.32 to 36.97 min, achieved a 48% improvement. Keywords SMED · Fuzzy FMEA · Reducing setup time · Lean production
Introduction The setup process not only extent production time but also negatively affects product quality and customer satisfaction and it does not add any value to the product. It is known that the setup times are very long especially in the companies producing different kinds of products. Therefore, companies aim to reduce setup time to make more flexible the production line and thus respond more quickly to changing requirements of the customer. The setup time reduction can be achieved using, single minute exchange of die (SMED), which is a common method. The SMED method makes it possible to perform equipment setup (changeover) operations in less than 10 min, i.e., in
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Kübra Yazıcı [email protected] Seda Hatice Gökler [email protected] Semra Boran [email protected]
1
Department of Industrial Engineering, Türkisch-Deutsche Universität, Istanbul, Turkey
2
Department of Industrial Engineering, Sakarya University, Sakarya, Turkey
the number of minutes expressed by a single digit (Shingo 1985). It allows us to quickly pass from after finishing processing a product to the next new product processing during the manufacturing process. In the literature, some studies contain the SMED method has successfully implemented in various industries such as textile processing (Moxham and Greatbanks 2001) automotive (Cakmakci 2009), electronic assembly (Trovinger and Bohn 2005
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