1. An-najah National University
Faculty of Engineering
Industrial Engineering Department
Project Title:
SMED (Single Minute Exchange of Die) System

2. Supervisor Name: Eng. Tamer Haddad Prepared by :
Deyala Hanbali Nosayma Sahban
Afnan Abu-Alhiega Reem Ismaeel

3. Outline Introduction Description Current die exchange Analysis
Setup
SMED
Description
Extrusion Process Description
Dies Description
Current die exchange Analysis
Assessment of the SMED methodology in NAPCO
Recommendation

4. SMED system
Single-Minute Exchange of Die is one of the many lean production methods for reducing waste in a manufacturing process.

5. 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.

6. 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.

7. Case study NAPCO different dies needed Means: set up time
produces different types of products
different dies needed
Means: set up time
waste of time
increased cost.

8. 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

9. 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.

10. Setup

11. 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 (Shingo,

12. 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

13. Internal setup External setup
Defined as the elements or work that must be carried out while the machine or equipment is shut down
External setup
defined as set-up elements which can take place while the machine is in operation or after the operation is completed

14. 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

15. Description

16. 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.

17. 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.

18. Aluminum Extrusion Process

19. 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.
Hollow dies
Flat dies

22. Current Die exchange analysis

23. 24 hour in day Three shifts
Work time
24 hour in day
Three shifts
Each hour costs 700$
24 days in month

24. In current state 500 different dies
with an average of exchanging 13 dies per day
with an average 8.98 minutes for each

25. Sample of calculation
13 changes * 8.98 min/change = 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

26. Task
Flat die(sec)
Hollow die(sec)
Min
Max
Std
Avg
max
Cut the last butt end and stop the machine and open die slide
6.350
28.120
5.317
13.682
10.350
43.110
8.55
20.794
Remove the old die by the crane and put it on the floor
11.42
77.050
16.529
36.676
15.930
79.220
17.4
37.725
Place insert in the machine by the crane to support the die
14.53
80.370
14.342
32.836
15.430
116.27 28
44.692
Remove the crane to dies furnace
24.30
50.730
6.753
31.163
9.542
88.340
14.9
30.172
get the new die from furnace and place it in the machine
12.13
73.550
15.978
40.634
20.100
111.68
23.3
46.697
close die slide and turn on machine
11.13
65.130
12.967
23.420
16.060
57.450
10.9
28.184
Extrude the first profile and handle it by the gripper
29.07
21.082
60.343
40.380
176.06
44.1
91.229
Inspect the extruded profiles by the crane and the angle
125.0
83.245
268.97
75.030
359.03
73.7
Total time
233.9
507.72
202.82
1031.2

27. flat die

32. Assessment of the SMED
methodology in NAPCO

33. Stage 0(Internal and External setup):
Die
assembly
Transfer
the
Die to
Transfer to storage
Take
out the
old die
Test
the new setup
Clean the old die
Insert
new die
Preheat
The die
0.328%
0.813%
56.879%
0.168%
0.197%
1.678%
39.612%
0.325%

34. E E E I I E E E Stage 1: Separating internal and external setup: Take
Die
assembly
Take
out the
old die
Transfer
the
Die to
Transfer to storage
Test
the new setup
Clean the old die
Insert
new die
Preheat
The die E E E I I E E E

35. Setup Checklist NO Yes Questions No. The die well cleaned1
The die assembled in the correct way 2
Proper die in the furnace 3
The die reach the specific temperature 4
Availability of proper insert 5
Availability of the crane beside the machine 6
The operator ready to change the die 7
The responsibility for everyone mineddeter 8

36. Stage 2: Converting the internal setup to external setup
several types of waste can occur
NAPCO Procedure
SMED 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

37. Once set-up is started, blades, dies, jigs, etc are discovered to be defective or not ready to run the next job. This creates lost time as you fix tooling, and start all
Select die and proper insert to match product/process specification before production plan of the current die ends and turn off the machine
Acceptable
Tooling that is needed for setting up is not located within the work station or placed in a planned, orderly location as required to prevent stopping and locating tools.
tooling that is needed for setting up is usually located near the work station but sometimes the crane isn’t available.
The operator who responsible to change the die often not available .
Need Improvement

38. No “Discretionary Time” taken by operator during internal set-up time
“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

39. 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

40. Streamlining all aspects of the setup operation:

41. Recommendation

42. 1. Add another crane 39.612% 0.328% 0.813% 56.879% 0.168% 0.197%
Shut down the machine and open die slide
Inspect the extruded profiles
Place insert in the machine
Remove the crane to dies furnace
Insert
new die
close die slide
Remove
the old die
get the new die
39.612%
0.328%
0.813%
56.879%
0.168%
0.197%
1.678%
0.325%

43. 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

44. Recommendation
4. Determine who is the responsible for exchanging the die and to identifying clear responsibilities for each worker

45. 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

46. 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

47. The method of the work

48. 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