PROJECT INFORMATION

Singe Minute Exchange of Die

46% Reduction in Changeover Time In Injection Molding DPL-2

Muhammad Mahmood Mansoor

Engineer Injection Molding DPL-2

Sensitivity: Public 1
 Process Flow of Changeover
Root Cause Analysis Target Setting Action Plan Cost Benefits Analysis Results Standardization / Verification

Arrangement of
Cleaning mold and Arrangement of
mold and crane
applying anti rust guiding ring
near machine

Last shot & purging
Disassembling of
Removal of mold from Insertion of new mold
water and hydraulic Removal of clamps Clamping of mold
machine in the machine
network

Removal of tools from

machine

Fitment of water Fitment of hydraulic Looping of hydraulic Removal of previous

Core setting Mold Adjustment
connections lines network mold from machine

External In Q2,3,4

Internal

Connection of Phase 2 In Q3,4

Checking of mold Purging and part
Checking of heaters temperature Production
gates setting
controller Parallel

Sensitivity: Public 2
 Fishbone Analysis of High changeover time
Root Cause Analysis Target Setting Action Plan Cost Benefits Analysis Results Standardization / Verification

Man Material Mold not available near machine C

Electrical team not available N Hot runner controller not available N
Unskilled mold loaders P Tools not available
N
Manpower not available - absenteeism
N Guiding ring not available N
Worker laziness
C
High changeover time
Extensive hydraulic looping
C Faulty temperature controller
N
Hydraulic connections
P Faulty heaters of mold
N
Water connections P Mold setting
P
Multiple mold loading at a time
C Faulty thermocouples resulting in dual timer usage
N
Installation and deinstallation of clamps manually
P
Checking of heaters P External In Q2,3,4

Removal of mold from machine

P N Noise Internal

Method Machine
C Control Investment In Q3,4

P Procedural
Parallel
Sensitivity: Public 3
 Proposed Corrections Phase wise
Root Cause Analysis Target Setting Action Plan Cost Benefits Analysis Results Standardization / Verification

Potential Potential
Potential Cause(s)/ D RP Recommended
S.no Item / Function Failure Effect(s) Sev occ Current Design Controls
Mechanism(s) of Failure et N Action(s)
Mode(s) of Failure

LOOPING OF HYDRAULIC
NETWORK
10 LOOPING DONE MANUALLY 4 240 LOOPING OF MOLDS BY TOOL ROOM

ASSEMBLING OF WATER
10 LOOPING DONE MANUALLY 4 240 LOOPING OF MOLDS BY TOOL ROOM
NETWORK

PRODUCTIVITY 1
3 MOLD LOADING SLOW LOADING
LOSS
6 CLAMPING OF MOLD 10 NONE
0
600 HYDRAULIC CLAMPS

1
CHECKING HEATERS 10 NONE
0
600 HEATER CHECKING BEFORE MOLD LOADING

UNSKILLED MANPOWER 2 NONE 7 84 HIRING OF SKILLED & LITERATE WORKERS

Sensitivity: Public 4
 400T/600T/850T/1050T
Root Cause Analysis Target Setting Action Plan Cost Benefits Analysis Results Standardization / Verification

400T/600T/850T/1050T
120.0% 16 120 min

14
97.5% 100.0%
100.0%

90.0% 92.5% 95.0% 12

86.7%
82.5%
80.0%
78.3%
74.2% 10
67.5%
60.0% 60.0% 8 External In Q2,3,4

50.0% Internal
6
37.5%
40.0%

4
Phase 2 In Q3,4
25.0%
20.0%
2
12.5%
0.0% 0

Time per Activity (min) Commulative %

Sensitivity: Public 5
 1600T/2600/2500T
Root Cause Analysis Target Setting Action Plan Cost Benefits Analysis Results Standardization / Verification

1600T/2600T/2500T
45
240 min
120%

40
100%
96% 98% 100%
94% 35
90% 92%
85%
80% 81% 30
77%
71%
25
65%
60%
56% 20
External In Q2,3,4
48%
Internal
40% 40% 15

29% 10 Phase 2 In Q3,4

20%
17% 5

0% 0

Time per activity (min) Commulative %

Sensitivity: Public 6
 Proposed Corrections Phase wise
Root Cause Analysis Target Setting Action Plan Cost Benefits Analysis Results Standardization / Verification

Internal to External – Phase 1 Activity Improvement Investment - Phase 2 Activity Improvement

Internal Activities External Activities ROOT CAUSE CORRECTIVE ACTION Status Cost
Disassembling of water and hydraulic Looping of hydraulic network
network
Waiting for
Clamping of the new mold Checking of heaters Hydraulic Installation of CAM quotation to
connections Couplers conduct cost
Purging and part setting Removal of previous mold from machine benefit analysis
Checking of mould gates

Removal of clamps
Waiting for
Water Installation of CAM quotation to
Fitment of hydraulic lines
connections Couplers conduct cost
Fitment of water connections benefit analysis
last shot and purging

Connection of temperature controller

1) Magnetic
Insertion of new mold in the machine Installation and
deinstallation clamping Arranging
Removal of mold from machine 2) Hydraulic
of clamps clamping quotations
manually 3) Power tools
Core setting

Mould Adjustment

Sensitivity: Public 7
 400/600/850T/1050T Phase Comparison
Root Cause Analysis Target Setting Action Plan Cost Benefits Analysis Results Standardization / Verification

Current Phase 1 Phase 2 Total reduction In Internal to

Activities improved Improved % Reduction External
Activity Time Activity Times Activity Times Activity Time

Looping of hydraulic network 15 0 0 15 100%

Disassembling of water and hydraulic network 15 15 7.5 7.5 50% Investment

Clamping of the new mold 15 15 7.5 7.5 50%

Removal of clamps 15 15 7.5 7.5 50%
Fitment of hydraulic lines 12 12 7.5 4.5 38%
Fitment of water connections 9 9 4.5 4.5 50%
Checking of mould gates 8 8 8 0 0%
Purging and part setting 5 5 5 0 0%
Checking of heaters 5 0 0 5 100%
last shot and purging 5 5 5 0 0%
replacing old mold with new 4 4 4 0 0%
Connection of temperature controller 3 3 3 0 0%
Removal of mold from machine 3 3 3 0 0%
Core setting 3 3 3 0 0%
Mould Adjustment 3 3 3 0 0%
Total Time 120 100 68.5 51.5 43%

Sensitivity: Public 8 17% 26%

 1600T/2600/2500T Phase Comparison
Root Cause Analysis Target Setting Action Plan Cost Benefits Analysis Results Standardization / Verification

Current Phase 1 Phase 2 Total reduction In

Activities Activity Time improved Improved Activity Time % Reduction Internal to
Activity Times Activity Times External

Looping of hydraulic network 40 0 0 40 100%

Disassembling of water and hydraulic network 30 30 15 15 50%
Investment
Clamping of the new mold 25 25 12.5 12.5 50%
Fitment of hydraulic lines 20 20 10 10 50%
Fitment of water connections 20 20 10 10 50%
Removal of clamps 20 20 10 10 50%
Checking of mold gates 15 15 15 0 0%
Checking of heaters 15 0 0 15 100%
Purging and part setting 10 10 10 0 0%
last shot and purging 10 10 10 0 0%
Connection of temperature controller 10 10 10 0 0%
Insertion of new mold in the machine 5 5 5 0 0%
Removal of mold from machine 5 5 5 0 0%
Core setting 5 5 5 0 0%
Mold Adjustment 5 5 5 0 0%
Removal of previous mold from machine 5 0 0 5 100%
Total Time 240 180 122.5 117.5 49%

Sensitivity: Public 9 25% 24%

 Overall Comparison Molding DPL-2
Root Cause Analysis Target Setting Action Plan Cost Benefits Analysis Results Standardization / Verification

Changeover Targets Quarter Wise - 2021

660 660

520 520
Changeover Times (mins)

240 240
356
180 180

122.5

120 120
100 100
68.5

YTD 2020 Q1 Q2 Q3 Q4

Quarter

400T/650T/850T/1050T 1600T/2600/2500T
Sensitivity: Public 10
 Overall Comparison Molding DPL-2
Root Cause Analysis Target Setting Action Plan Cost Benefits Analysis Results Standardization / Verification

  Minutes per loading 136 81 55

Machines current improved loadings per month current (mins) improved (mins) savings (mins)

400/650/850/1050 120 68 130 15600 8840 6760

1600/2600 240 165 20 4800 3300 1500

 
 Total 150 20400 12140 8260
 

Sensitivity: Public 11
 Action Plan
Root Cause Analysis Target Setting Action Plan Cost Benefits Analysis Results Standardization / Verification
TITLE PLANNED ACTUAL

SMED - Injection Molding

PROJECT DAYS 152
PROJECT START TIME 01-Mar-2021 01-Mar-2021
PRODUCTION DPT
PROJECT END TIME 31-Jul-2021

2020

S.N TASK DESCRIPTION Mar-20 Apr-20 May-20 Jun-20 Jul-20

W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3 W4

PLANNED
1 Define CTQ diagram + Project Charter
ACTUAL
PLANNED
2 Measure video capturing
ACTUAL
PLANNED
3 Measure time and motion study
ACTUAL
PLANNED
4 Measure Process flow charts (low level mapping)
ACTUAL
PLANNED
5 Measure Identification of Internal and External Activities
ACTUAL
PLANNED
6 Analyse pareto analysis to identify most time consuming activites
ACTUAL
PLANNED
7 Analyse RCA of bottlenecks (with wastes highlighted)
ACTUAL
streamlining of external activities and removing wastes - PLANNED
8 Improve
phase 1 (low investment) ACTUAL
Optimization of internal activities by simplifying - phase 2 PLANNED
9 Improve
(high investment) ACTUAL
PLANNED
10 Improve Implementation of investments
ACTUAL
PLANNED
11 Improve validation - gauging improvement
ACTUAL
PLANNED
12 Control formulation of check sheets
ACTUAL
standardisation via SOPs, Control Plan, Operational PLANNED
13 Control
Instruction etc ACTUAL
PLANNED
14 Control updation of data capturing and data collection formats
ACTUAL
PLANNED
15 Control Updatation of calibration records
ACTUAL

Sensitivity: Public
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 Departmental Impact – Phase 1 & 2
Root Cause Analysis Target Setting Action Plan Cost Benefits Analysis Results Standardization / Verification

Phase 1
Improvement 4,028 Hours 15,420 KWHs 9,052 Hours
Savings

Phase 2
Improvement 3,503 Hours 16,397 KWHs 8,746 Hours
Savings

Machines Availability (Hours) KWHs Saving Manhours Saving

Combined Savings 7,531 Hours 32,357 KWHs 17,798 Hours

Sensitivity: Public
Sensitivity: Public 14