Production Process Time Reduction Strategy through SMED Method Implementation

Andi Dwi Wahyu Wibowo, Taufik Rachmad Fauzy, Surjo Hadi

Abstract

The increasingly competitive manufacturing industry demands companies to improve operational efficiency, particularly in the changeover process, which contributes to production downtime. This study aims to analyze the application of the Single Minute Exchange of Dies (SMED) method in reducing setup time in the packaging process to improve production efficiency. The study uses a quantitative approach through direct observation, measuring work time, identifying internal and external setup activities, converting internal activities to external ones, and simplifying non-value-added activities. The results show that the application of SMED can reduce setup time from 265 minutes to 180 minutes, a reduction of 85 minutes (32%). Improvements were made through optimizing the mold installation process, which saved 20 minutes, improving eyemark settings, which reduced the time by 5 minutes, and improving cutter settings, which reduced the duration from 120 minutes to 60 minutes. The research findings prove that the SMED method is effective in increasing the efficiency of the changeover process, reducing production downtime, and increasing productivity in the packaging process. This study provides a practical contribution as a reference for the application of SMED in an effort to improve operational performance in manufacturing industries with similar product changeover characteristics.

Keywords

Keywords: Packaging, Product Changeover, Productivity, SMED, Time Efficiency.

Full Text:

PDF

References

P. Sivaraman, T. Nithyanandhan, S. Lakshminarasimhan, S. Manikandan, and M. Saifudheen, “Productivity enhancement in engine assembly using lean tools and techniques,” in Materials Today: Proceedings, Elsevier Ltd, Jan. 2020, pp. 201–207. doi: 10.1016/j.matpr.2020.04.010.

A. D. W. Wibowo, Mokh. Suef, and P. D. Karningsih, “FTA-FMEA and Pokayoke Analysis to Reduce Stamping Machine Breakdown Time,” 2024, pp. 205–221. doi: 10.2991/978-94-6463-566-9_15.

S. Bhade and S. Hegde, “Improvement of Overall Equipment Efficiency of Machine by SMED,” 2020. [Online]. Available: www.sciencedirect.comwww.materialstoday.com/proceedings2214-7853

Y. Kose, H. N. Civan, E. Ayyildiz, and E. Cevikcan, “An Interval Valued Pythagorean Fuzzy AHP–TOPSIS Integrated Model for Ergonomic Assessment of Setup Process under SMED,” Sustainability (Switzerland), vol. 14, no. 21, Nov. 2022, doi: 10.3390/su142113804.

V. Parwani and G. Hu, “Improving Manufacturing Supply Chain by Integrating SMED and Production Scheduling,” Logistics, vol. 5, no. 1, Mar. 2021, doi: 10.3390/logistics5010004.

J. R. Díaz-Reza, J. L. García-Alcaraz, V. Martínez-Loya, J. Blanco-Fernández, E. Jiménez-Macías, and L. Avelar-Sosa, “The effect of SMED on benefits gained in maquiladora industry,” Sustainability (Switzerland), vol. 8, no. 12, 2016, doi: 10.3390/su8121237.

D. Ribeiro, F. Braga, R. Sousa, and S. Carmo-Silva, “An Application of the SMED Methodology in an Electric Power Controls Company.”

R. Fritsche, “Reducing set-up times for improved flexibility in high-mix low-volume electric drives production,” in 2011 1st International Electric Drives Production Conference, IEEE, Sep. 2011, pp. 74–77. doi: 10.1109/EDPC.2011.6085553.

A. Kumar Tilkar, P. R. Nagaich, and A. K. Marwah, “Improving Productivity of a Manufacturing Plant using Single Minute Exchange of Die”, [Online]. Available: http://www.rspublication.com/ijst/index.htmlhttp://www.rspublication.com/ijst/index.html

J. G. M. ; R. G. A. ; C. L. L. V. León, “Implementación de la Metodología Smed (Single Minute Exchange of Die) Como Soporte al Sistema Kanban en un Proceso de Fabricación de Autopartes, Bajo un Enfoque de Valoración y Gestión del Capital Intelectual,” http://www.concyteg.gob.mx/formulario/MT/MT2009/MT5/SESION1/MT51_JM ENDOZA_078.pdf (assessed on 28 October 2016)., 2016.

Berna Ulutas, “An application of SMED methodology,” World Academy of Science, Engineering and TechnologyInternational Journal of Mechanical, Aerospace, Industrial, Mechatronic and Manufacturing Engineering , vol. 5, no. 7, Jul. 2011.

R. M. Sousa, R. M. Lima, J. D. Carvalho, and A. C. Alves, “An industrial application of resource constrained scheduling for quick changeover,” in 2009 IEEE International Conference on Industrial Engineering and Engineering Management, IEEE, Dec. 2009, pp. 189–193. doi: 10.1109/IEEM.2009.5373391.

V. Kumar and A. Bajaj, “International Journal on Recent Technologies in Mechanical and Electrical Engineering (IJRMEE) The Implementation of Single Minute Exchange of Die with 5’S in Machining Processes for reduction of Setup Time,” 2015, [Online]. Available: http://www.ijrmee.org

B. J. Singh and D. Khanduja, “SMED: For quick changeovers in foundry SMEs,” International Journal of Productivity and Performance Management, vol. 59, no. 1, pp. 98–116, Jan. 2010, doi: 10.1108/17410401011006130.

A. Silva, J. C. Sá, G. Santos, F. J. G. Silva, L. P. Ferreira, and M. T. Pereira, “Implementation of SMED in a cutting line,” in Procedia Manufacturing, Elsevier B.V., 2020, pp. 1355–1362. doi: 10.1016/j.promfg.2020.10.189.

M. Braglia, F. Di Paco, and L. Marrazzini, “A new Lean tool for efficiency evaluation in SMED projects,” International Journal of Advanced Manufacturing Technology, vol. 127, no. 1–2, pp. 431–446, Jul. 2023, doi: 10.1007/s00170-023-11508-9.

I. Mhm and R. Mna, “Setup Time Reduction in an Automotive Battery Assembly Line,” 2011.

R. Sahin and A. Kologlu, “A Case Study on Reducing Setup Time Using SMED on a Turning Line,” Gazi University Journal of Science, vol. 35, no. 1, pp. 60–71, 2022, doi: 10.35378/gujs.735969.

E. Sousa, F. J. G. Silva, L. P. Ferreira, M. T. Pereira, R. Gouveia, and R. P. Silva, “Applying SMED methodology in cork stoppers production,” in Procedia Manufacturing, Elsevier B.V., 2018, pp. 611–622. doi: 10.1016/j.promfg.2018.10.103.

C. Monteiro, L. P. Ferreira, N. O. Fernandes, J. C. Sá, M. T. Ribeiro, and F. J. G. Silva, “Improving the Machining Process of the Metalworking Industry Using the Lean Tool SMED,” Procedia Manuf., vol. 41, pp. 555–562, 2019, doi: 10.1016/j.promfg.2019.09.043.

T. Vieira et al., “Optimization of the cold profiling process through SMED,” in Procedia Manufacturing, Elsevier B.V., 2019, pp. 892–899. doi: 10.1016/j.promfg.2020.01.171.

A. M. Vieira, F. J. G. Silva, R. D. S. G. Campilho, L. P. Ferreira, J. C. Sá, and T. Pereira, “SMED methodology applied to the deep drawing process in the automotive industry,” Procedia Manuf., vol. 51, pp. 1416–1422, 2020, doi: 10.1016/j.promfg.2020.10.197.

A. Dwi Wahyu Wibowo, J. Teknik Industri, and F. Teknologi Industri, “Implementasi Metode Single Minute Exchange of Dies (SMED) dan Maynard Operation Sequence Technique (MOST) untuk Perbaikan Waktu Proses Produksi (Studi Kasus Departemen Produksi-Wrapping di PT. X Surabaya).”

G. F. I. Toki et al., “Single Minute Exchange Die (SMED): A sustainable and well-timed approach for Bangladeshi garments industry,” Clean. Eng. Technol., vol. 12, p. 100592, Feb. 2023, doi: 10.1016/j.clet.2022.100592.

S. E. Lino Moreno, B. L. Navarro Ayola, R. Salas, and S. Nallusamy, “Enhancement of Operational Efficiency in a Plastic Manufacturing Industry Through TPM, SMED, and Machine Learning—Case Study,” Sustainability, vol. 17, no. 16, p. 7445, Aug. 2025, doi: 10.3390/su17167445.

S. Sousa, M. M. Silva, and P. D. Gaspar, “Implementation of SMED Workshops: A Strategic Approach in the Automotive Sector,” Applied Sciences, vol. 15, no. 16, p. 8943, Aug. 2025, doi: 10.3390/app15168943.

G. Tuncel, G. Yildiz, N. Akcal, and G. Korkmaz, “Optimizing Wind Turbine Blade Manufacturing Using Single-Minute Exchange of Die and Resource-Constrained Project Scheduling,” Processes, vol. 13, no. 7, p. 2208, Jul. 2025, doi: 10.3390/pr13072208.

V. Santos et al., “Applying the SMED Methodology to Tire Calibration Procedures,” Systems, vol. 10, no. 6, p. 239, Dec. 2022, doi: 10.3390/systems10060239.

DOI: https://doi.org/10.31284/j.jtm.2026.v7i2.9252

Refbacks

  • There are currently no refbacks.