REDUCING CHANGEOVER TIME ON INJECTION MOLDING MACHINE BY USING SINGLE MINUTE EXCHANGE OF DIES (SMED) METHOD

Abstract

This thesis is aimed to reduce the changeover time of machine in injection molding process of a toy manufacturing. High changeover time in injection molding machine could give impact to the machine efficiency and flexibility. In order to overcome the root cause, the Single Minute Exchange of Die (SMED) is the first and foremost method to be done. SMED is a concept and method was developed by Shigeo Shingo to reduce changeover time. Before SMED method is applied, the observation and time study of the current flow process in injection molding machine changeover is conducted. Furthermore, some lean tools like 5S implementation cause and effect diagram, value added and non-value added determination are considered in reducing injection molding machine changeover time. Those methods can increase the efficiency of internal and external operations. By implementing those methods, there are many improvements can be achieved. The injection molding machine changeover time is reduced by 37% from the previous changeover time (from 39.62 minutes to 24.88 minutes). Furthermore, the 5S score is increased by 0.94 points (from 2.09 points to 3.03 points). As a result, the problem of high changeover time in injection molding machine and having additional cost can be overcome.