v
TABLE OF CONTENTS
Abstract i
Abstrak ii
Dedication iii
Acknowledgement iv
Table of Content v
List of Tables viii
List of Figures ix
List of Abbreviations
xi CHAPTER 1: INTRODUCTION
1
1.1 Background of Study 1
1.2 Problem Statement 2
1.3 Objectives of the Study 3
1.4 Scopes of the Study 3
CHAPTER 2: LITERATURE REVIEW 4
2.1 Overview 4
2.2 Lean Manufacturing 4
2.2.1 Seven Waste of Lean Manufacturing 6
2.2.2 Lean Principles 8
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2.2.3 Lean Tools 9
2.2.3.1 5S 12
2.2.3.2 Andon 14
2.2.4 Manufacturing Lead Time 14
2.3 Single Minute Exchange of Dies SMED 15
2.3.1 Machine Setup 16
2.3.1.1 Setup Waste 17
2.3.2 The Importance of SMED 17
2.3.3 The Setup Reduction via SMED Method 18
2.3.4 SMED Benefits 21
CHAPTER 3: METHODOLOGY 23
3.1 Introduction 23
3.2 Project Flow Chart 24
3.2.1 Relationship between Objectives and Methodology 25
3.3 Project Procedure 25
3.4 Report Writing 27
3.5 Data Collection and Analysis 27
3.5.1 Qualitative Data 27
3.5.2 Secondary Sources for Data Collection 28
3.5.2.1 Journals Articles 28
3.5.2.2 Books 29
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3.5.2.3Internet 29
CHAPTER 4: RESULT AND DISCUSSION 30
4.1 Existing Changeover Process 30
4.1.1 Problems Identified During Changeover Process 36
4.2 Applied SMED 38
4.3 Propose Ideas for Changeover Improvement 39
4.3.1 SMED Methodology 39
4.3.2 Visual managementLabelling 41
4.3.3 Andon 43
4.4 Propose New Changeover Process 45
4.5 Results 48
CHAPTER 5: CONCLUSION AND RECOMMENDATION 51
5.1 Conclusion 51
5.2 Recommendations for Future Work 53
REFERENCES 54
APPENDICES
Appendix A: Gant Chart PSM 1 PSM 2
viii
LIST OF TABLES
Table 2.1 Types of manufacturing waste 7
Table 2.2 List of Lean Tools 10
Table 2.3 SMED conceptual framework 19
Table 3.1 Table of relationship 25
Table 4.1 Changeover time for current changeover 35
Table 4.2 Setup step define 38
Table 4.3 Lists of activities for new changeover 40
Table 4.4 Checklist for storage 43
Table 4.5 Activities for new changeover process 45
Table 4.6 Improvements for the current changeover 46
Table 4.7 Estimated times for new changeover 49
Table 4.8 Streamlined for internal activities 50
Table 4.9 Streamlined for external activities 50
ix
LIST OF FIGURES
Figure 2.1 The phases of SMED methodology 20
Figure 2.2 Benefits of SMED 22
Figure 3.1 Project flow chart 24
Figure 4.1 Flowchart of current procedure 31
Figure 4.2 Finishing the packaging 32
Figure 4.3 Operator clears the table 32
Figure 4.4 Operator clears the bowl feeder 32
Figure 4.5 Operator puts new pins 32
Figure 4.6 Technician loosen the screws 33
Figure 4.7 Prepares new base 33
Figure 4.8 Tighten the screws 33
Figure 4.9 Load the new base 33
Figure 4.10 Trial runs and adjustments 34
Figure 4.11 Setting the weight 34
Figure 4.12 Operator do the quality check 34
Figure 4.13 Operator put barcode stickers 34
Figure 4.14 Prepare the table 34
Figure 4.15 Current changeover charts 36
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Figure 4.16 Storage for base and receiver 37
Figure 4.17 Proposed tags for base and receiver 42
Figure 4.18 Types of signal light 44
Figure 4.19 Flowchart for proposed changeover 47
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LIST OF ABBREVIATIONS
JIT- Just In Time SMED- Single Minute Exchange of Dies
TPM- Total Productive Maintenance TPS- Toyota Production System
WIP- Work in Process
1
CHAPTER 1 INTRODUCTION
