In very customized production systems, even long pre-assembly changeovers continue to constrain productivity and on-target delivery. This research explores the extent to which Single Minute Exchange of Dies (SMED) can be embedded within a DMAIC methodology to reduce internal changeover periods throughout an assembly line. Through video analysis and interviews with floor-level employees, we were able to determine and quantify internal changeovers, also isolating non-value-added activity. Root cause analysis suggested operator movement and transport preparation, or better, its elimination through sharing and design, as an area of focus. The important message here is that internal changeovers can be reduced without investing heavily or changing layouts and equipment configurations.

Keywords

Single Minute Exchange of Dies (SMED); Pre-assembly changeover; Lean manufacturing; DMAIC; Setup time reduction