Productivity improvement by reducing the tool change time using SMED methodology

Abstract

SMED (Single Minute Exchange of Die) is one of the many Lean production methods for reducing time in a manufacturing process. The present paper deals with reduction in tool change time in one of the prime automotive batteries industry using SMED technique which increases productivity of the industry. In this project first the problem is identified in SBD (Small Battery Division) Plant based on analysis of one month data of plant capacity. After analysis, the bottleneck is identified for production of the plant using Pareto Analysis which indicates that the maximum tool change time due to Calibration and Assembly. Next SMED Methodology implemented on major areas to reduce the tool change time. The causes for recursive activities searched and ideas implemented to eliminate them provided. After implementing SMED technique the total tool change time for Calibration from 2192 to 1194 seconds and Assembly from 42 to 24 minutes reduced.