An-najah National University Faculty of Engineering Industrial Engineering Department

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 • 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

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 1955 (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 • 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

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 = 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

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 Clean the old die Take out the old die Test the new setup Insert new die Preheat The die 0.328% 0.813% 56.879% 0.168% 0.197% 1.678% 39.612% 0.325%

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

36. Stage 2:Converting the internal setup to external setup

40. Streamlining all aspects of the setup operation:

41. Recommendation

42. 1. Add another crane 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 3. Training the workers and motivated them to increase the productivity and loyalty for the company and to follow the instructions 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

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