An integrated SMED-fuzzy FMEA model for reducing setup time

Abstract

Today, the companies apply lean or customized production methods, which enable the production of different kinds of products in small quantities, to meet different customer demands. But, the increase in the product variety leads to an increase in the number of setups and thus production time. The companies aim to reduce the setup time by improving activities and by eliminating the problems causing extending setup time. Single minute exchange of die (SMED) method is the most common setup method that makes it possible to perform equipment setup operations in fewer than 10 min, i.e. several minutes expressed by a single digit. It is possible to further reduce setup times by integrating quality tools and methods into the SMED method. In this study, it is developed a novel SMED model that integrating the traditional SMED and fuzzy failure modes and effects analysis (fuzzy-FMEA) methods. Fuzzy FMEA method is used to prevent problems causing further extending setup time on setup activities. A new operation worksheet, "Setup Observation and Analysis Form" that leads the analyst in during the investigation of the machine and its set-up process, is also designed. The new approach is applied to set up a plastic injection mold for a pen manufacturing company. The setup time is reduced from 71.32 to 36.97 min, achieved a 48% improvement.