Changeover Time Reduction and Productivity Improvement by Integrating Conventional SMED Method with Implementation of MES for Better Production Planning and Control

This paper addresses a setup time reduction through SMED with an integration of MES (planning system interface). Reduction of changeover time has always been critical in most of the manufacturing industries. Most of the changeover or setup time reduction are governed or associated with Shingo’s Single Minute Exchange of Die(SMED) method that suggest the conversion of internal setup operations to external operations. SMED has been initiated by most of the companies but failed to implement it. The basic reason behind this is the strict application of SMED method which does not follow the systematic approach to implement this conversion and also it is not the best method to reduce the setup time in all the circumstances and situations. In this paper SMED integration with MES (which deals with Planning System Interface) is presented that has been developed specifically for an automotive supplier. The validation of the proposed method was done through implementation on manufacturing company which manufactures radiator, compressor and HVAC. The methodology used is SMED method with MES which deals with strategic definition and preparatory activities. It also includes communication which should be two ways so as the MES can keep the planning system properly informed about activities such as labour data, inventory changes, work order progress, project targets and timescale definition, selection of the appropriate team and coordinator, allocation of specific roles and responsibilities to each team member, training of team and shop floor staff on the new methodology and changeover standards. By implementing the SMED with MES improvement programme, the company achieved much reduction on changeover time which led to the increase in high productivity.