An-najah National University
Faculty of Engineering
Industrial Engineering Department
Project Title:
SMED (Single Minute Exchange of Die) System
Supervisor Name: Eng. Tamer Haddad
Prepared by :
Deyala Hanbali
Nosayma Sahban
Afnan Abu-Alhiega
Reem Ismaeel
Outline

Introduction
Setup
 SMED


Description
Extrusion Process Description
 Dies Description




Current die exchange Analysis
Assessment of the SMED methodology in NAPCO
Recommendation
SMED system
Single-Minute Exchange of Die is one of the many lean
production methods for reducing waste in a
manufacturing process.
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.
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.
dies
needed
Case study
NAPCO
waste of
time
• produces
different
types of
products
• Means:
set up time
• increased
cost.

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
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.
Setup
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
1955 (Shingo,
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
Internal
setup
External
setup
• Defined as the elements or
work that must be carried
out while the machine or
equipment is shut down
• defined as set-up elements
which can take place while
the machine is in operation
or after the operation is
completed
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
Description
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.

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.
Aluminum Extrusion Process
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.
Flat dies
Hollow dies
Current Die exchange
analysis
24 hour
in day
24 days
in
month
Work
time
Each hour
costs 700$
Three
shifts
In current state

500 different dies

with an average of exchanging 13 dies per day

with an average 8.98 minutes for each
Sample of calculation

13 changes * 8.98 min/change = 116.74 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
Task
Cut the last butt end
and stop the machine
and open die slide
Remove the old die by
the crane and put it on
the floor
Place insert in the
machine by the crane
to support the die
Remove the crane to
dies furnace
get the new die from
furnace and place it in
the machine
close die slide and turn
on machine
Extrude the first
profile and handle it
by the gripper
Inspect the extruded
profiles by the crane
and the angle
Total time
Min
Flat die(sec)
Max
Std
Avg
Min
Hollow die(sec)
max
Std
Avg
6.350
28.120
5.317
13.682
10.350
43.110
8.55
20.794
11.42
77.050
16.529
36.676
15.930 79.220
17.4
37.725
14.53
80.370
14.342
32.836
15.430
116.27
28
44.692
24.30
50.730
6.753
31.163
9.542
88.340
14.9
30.172
12.13
73.550
15.978
40.634
20.100
111.68
23.3
46.697
11.13
65.130
12.967
23.420
16.060 57.450
10.9
28.184
29.07
100.080
21.082
60.343
40.380 176.06
44.1
91.229
125.0
420.440
83.245
268.97
75.030 359.03
73.7
271.471
233.9
895.470
507.72
202.82 1031.2
570.964
flat die
Assessment of the
SMED
methodology in NAPCO
Stage 0(Internal and External setup):
Transfer
Die
the
assembly
Die to
0.328%
0.813%
Take
Preheat
out the
The die
old die
56.879%
0.168%
Insert
Test
the
new
die
0.197%
Clean
Transfer
the old
to
die
storage
new
setup
1.678%
39.612% 0.325%
Stage 1:
Separating internal and external setup:
Take
Transfer
Die
the
assembly
Die to
E
E
Preheat
The die
E
out the
old die
I
Insert
Test
the
new
Clean
Transfer
the old
to
storage
E
new
die
setup
die
I
E
E
Setup Checklist
No.
Questions
1
The die well cleaned
2
The die assembled in the correct
way
Proper die in the furnace
3
4
5
The die reach the specific
temperature
Availability of proper insert
6
Availability of the crane beside
the machine
7
The operator ready to change the
die
The responsibility for everyone
mineddeter
8
Yes
NO
Stage 2:
Converting the internal setup to external setup
several types of waste can
occur
NAPCO Procedure
Finished Goods are

transported to storage or the
next batch of raw materials are
Select proper die before shut down
the machine.

moved from storage into the
work station when the
SMED evaluation
Select
proper insert before shut
down the machine

The old machine is transferred while
machine is shut down
the machine is turn on. )
Acceptable
Select die and proper insert to match
dies, jigs, etc are discovered to
product/process specification before
be defective or not ready to
production plan of the current die ends
run the next job. This creates
and turn off the machine
Acceptable
Once set-up is started, blades,
lost time as you fix tooling, and
start all

tooling that is needed for setting up
is usually located near the work
setting up is not located within
station but sometimes the crane isn’t
the work station or placed in a
planned, orderly location as
required to prevent stopping
and locating tools.
available.

The operator
who responsible to
change the die often not available .
Need Improvement
Tooling that is needed for
“Discretionary
Time”

No “Discretionary Time” taken by
operator during internal set-up time
taken by operator during

No need to startup time because the Acceptable
production is continuous .

Next job is always ready because
internal set-up time
(when machine is idle) to
take breaks, eat, talk.
Next job is not ready and
they use preheating system that
operator has to wait for
softened
billets
prior
to
extrusion.
parts to come from the
supplying work center
the

Die storage have a clearly marked
and specific location. (Dies need to
always be returned to the same
location,
condition
in
“production
ready”
Acceptable
Parts that are no longer
The old die transported to Acceptable
needed are transported to
the tool room after turn
the tool room while the
on the machine
machine is turned off.
Start die heated after turn Also in preparation
off the machine
NAPCO use preheating in
order to reduce the time
that taken for setup
Acceptable
Streamlining all aspects of the setup
operation:
Recommendation
1. Add another crane
Place
Shut down
the
machine
Remove
insert in
the old die
the
machine
and open
Inspect
Remove
get the
Insert
close
to dies
new
new
die
furnace
die
die
slide
0.168%
0.197%
the crane
die slide
0.328%
0.813%
56.879%
1.678%
the
extruded
profiles
39.612% 0.325%
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
Recommendation
4. Determine who is the responsible for exchanging
the die and to identifying clear responsibilities for
each worker
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
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
The method of the work
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