SINGLE MINUTE EXCHANGE

OF DIES &
DE-BULGING FIXTURE
Presented by
Akshay Shah (6324)
Fr. Conceicao Rodrigues College of
Engineering

SINGLE MINUTE EXCHANGE OF

DIES

INTRODUCTION
The Single Minute Exchange of Die(SMED) methodology,
was developed in order to reduce and simplify the setup
time during change-over.
Need:
1. Increase time for Critical machines
2. Reduce No. of Lot Sizes.

OUTLINE

Lesson
Lesson
Lesson
Lesson
Lesson

1:
2:
3:
4:
5:

Methodology
Time Study
Problems & Solutions
Comparison Before & After
Result

Methodology
Modified Shingo Technique

To analyse the actual procedure

To classify the several operations performed as internal or
external ones
To develop solutions that allow to reduce the time of the
internal operations
To develop solutions that allow to decrease the time delays
in the external operations
To return to the beginning of the process and to repeat the
whole procedure to reduce the setup time, continuously.

TIME STUDY

PROBLEMS:
Forklift for loading/unloading
Locating
Clamping

Proposed Solutions:
Loading/Unloading
Call Forklift while removing clamps of previous DIE set.
Modification to an old loading trolley.
Locating
Center gauging by standardizing die base(fixed gauge)
Fixing a reference plate for locating the die on the bolster plate
Clamping
Designing standard die clamp block for every Die block, this will align with bed T-slot.
Pneumatic Wrench for fastening strap clamps.

Current loading trolley

Proposed Trolley Design

Standardizing of Dies for Alignment

Welded Extension plate and

Clamping Block

Current clamping practice

Clamping Block

Actual clamps laser cut and welded

Time Study after Implementation

OUTCOME
Time(secs)

Percentage

Before

Time(secs)

Percentage

After

Time saved = 35.25-18.1 =17.15 minutes per changeover

= 17.15*4
= 68.6 minutes per day
This time will be utilized by following operation; hence the number of components processed will be
more. Thus, the machine availability time was increased 68.6 minute per day

DE-BULGING FIXTURE

INTRODUCTION
Fixtures are important in both traditional manufacturing and modern flexible
manufacturing system (FMS), which directly affect machining quality, productivity
and cost of products
NEED:
1. Manufacturing of safes requires all the critical parameters to be within the
tolerances
2. While manufacturing of safes, concrete is filled between the inner body and
outer body of the safe
3. Concrete on solidifying, expands. Due to the expansion, the critical parameters
are affected and the sides of the safe bulges due to it.
4. This Bulging of the safe wall is unwanted and leads to rejection of the product.

OUTLINE

Lesson
Lesson
Lesson
Lesson

1:
2:
3:
4:

Process Study
Rework
Design of a fixture
Result

PROCESS STUDY
Manufacturing of Cen safe was analyzed during this study.
Different defects faced by the supervisors during the
manufacturing were studied thoroughly.
Defects that were observed were:
Dislocation
Dents
Bulging
Components not within the specified tolerance
Rusting
Paint run down

A batch of 10 safes were analysed and studied for different defects involved in manufacturing of
safes.
A graph was plotted with respect to no of repetition of defects.

Defects

REWORK:
Bulging

Hammering

Dent Formation

Extra care during

Surface Finishing
and Polishing

DESIGN

Fabricated Fixture

RESULT
Costing:
Labour cost Rs. 70/Kg
Toggle clamp costs Rs. 300/piece
Laser cutting machine working cost Rs. 2000/hour
Total weight of the fixture 4.5 kgs
Cost/fixture = 70*4.5 + 600 + 170
= Rs.1085
Monthly production = 40 pieces in a month with batch size of 3
Therefore required fixtures = 3+2(spare) = 5
Cost for 5 fixtures = 5*1085 = Rs. 5425
This is a onetime investment.

Rework Cost Saved/ Safe:

Man hours required: 1.5 hours
No of Men required: 2
Labour cost: Rs. 800/day
Therefore, Rework Cost = 1.5*2*100 = Rs.300/safe
Production aim is 40 units per month with a batch size of 3.
Thus, Rework cost saved on 40 safes is Rs. 12000
In addition to rework, quality acquired by the safe while manufacturing has
increased due to the usage of the De-Bulging fixture.

CONCLUSION
Single Minute Exchange of Dies (SMED) involves separation of internal
and external setups, converting internal setups to external and
reducing the no of setups. The necessary changes in internal setups
were made and the no of setups were reduced aptly. Total Die Setting
time was reduced by 50%. The project was carried out on 160 ton
power press machine. If the company works on the other machines
available to them, they can increase their Machine availability time and
thus increase productivity with ease and comfort.
De-Bulging Fixture was fabricated and used for manufacturing of safes.
Due to which, Bulging defect of the Cen safe was completely
eliminated. On a large scale, the De-bulging fixture has solved a lot of
problems for company and has made the manufacturing, hassle free.

THANK YOU