Proposal for the reduction of setup times in the EVA injection process in a company in the footwear sector through the implementation of the SMED methodology

Abstract

This article aims to present a proposal for the reduction of enlistment times in machine No. 4 of the injection molding area of a company in the footwear sector, using the SMED methodology, a fundamental tool of Lean Manufacturing. The basic application of the SMED methodology in this case study is carried out through four stages: i) the realization of a study of methods and times for the standardization of the enlistment process of machine, ii) the elaboration of the layout for the new distribution of the area, iii) the definition of the steps to apply the SMED methodology, and finally, iv) the use of discrete simulation for the assessment of the impact on enlistment times. Obviously, after carrying out the previous stages for the implementation of the proposal in the company, it is possible to reduce the enlistment time by 51,53 % and the daily effective production capacity is increased by 9,5 %.

El presente artículo tiene como objetivo presentar una propuesta para la disminución de los tiempos de alistamiento en la máquina No. 4 del área de inyección por moldeo en una empresa del sector del calzado, utilizando la metodología SMED, una herramienta fundamental del lean manufacturing. La aplicación básica de la metodología SMED, en este caso de estudio, se lleva a cabo a través de cuatro etapas: i) la realización de un estudio de métodos y tiempos para la estandarización del proceso de alistamiento de la máquina, ii) la elaboración del layout para la nueva distribución del área, iii) la definición de los pasos para aplicar la metodología SMED y, finalmente, iv) la utilización de la simulación discreta para la valoración del impacto en los tiempos de alistamiento. Después de realizar las etapas anteriores para la implementación de la propuesta en la empresa, se logra disminuir el tiempo de alistamiento en 51,53 % y se incrementa la capacidad efectiva diaria de producción en 9,5 %.

This article aims to present a proposal for the reduction of enlistment times in machine No. 4 of the injection molding area of a company in the footwear sector, using the SMED methodology, a fundamental tool of Lean Manufacturing. The basic application of the SMED methodology in this case study is carried out through four stages: i) the realization of a study of methods and times for the standardization of the enlistment process of machine, ii) the elaboration of the layout for the new distribution of the area, iii) the definition of the steps to apply the SMED methodology, and finally, iv) the use of discrete simulation for the assessment of the impact on enlistment times. Obviously, after carrying out the previous stages for the implementation of the proposal in the company, it is possible to reduce the enlistment time by 51,53 % and the daily effective production capacity is increased by 9,5 %.