Setup Analysis: Combining SMED with Other Tools

Abstract The purpose of this paper is to propose the methodology for the setup analysis, which can be implemented mainly in small and medium enterprises which are not convinced to implement the setups development. The methodology was developed after the research which determined the problem. Companies still have difficulties with a long setup time. Many of them do nothing to decrease this time. A long setup is not a sufficient reason for companies to undertake any actions towards the setup time reduction. To encourage companies to implement SMED it is essential to make some analyses of changeovers in order to discover problems. The methodology proposed can really encourage the management to take a decision about the SMED implementation, and that was verified in a production company. The setup analysis methodology is made up of seven steps. Four of them concern a setups analysis in a chosen area of a company, such as a work stand which is a bottleneck with many setups. The goal is to convince the management to begin actions concerning the setups improvement. The last three steps are related to a certain setup and, there, the goal is to reduce a setup time and the risk of problems which can appear during the setup. In this paper, the tools such as SMED, Pareto analysis, statistical analysis, FMEA and other were used. Implementing the proposed methodology can change the attitude of the management. The risk analysis helps to prevent problems with a setup. This methodology can be used in production companies which make changeovers, particularly, in the companies where SMED hasn't been introduced yet.