Abstract
This study aimed to identify the causes of significant problems existing in the metallurgical sector, and a solution is proposed for the setup process. We detail the theoretical background of the processes in the lean manufacturing methodology, which will be applied to a rolling machine. Further, we provide a brief description of the company and the sector’s problems. We describe success stories of companies that implemented various lean manufacturing tools. We also present some of the results achieved across sectors to gain an in-depth understanding of the technique and a practical support of the implemented model. Our proposal is based on the lean manufacturing methodology; tools such as Single Minute Exchanges of Dies, Kaizen, 5S, and value stream mapping (VSM) will be used to reduce setup times and to impact machine layout and productivity positively. We also show the implementation results of a pilot plan conducted in the company over a period of more than 3 months.
Access this chapter
Tax calculation will be finalised at checkout
Purchases are for personal use only
References
Belhadi, A., Touriki, F.E., El Fezazi, S.: Benefits of adopting lean production on green performance of SMEs: a case study. Prod. Plan. Control 29, 873–894 (2018). https://doi.org/10.1080/09537287.2018.1490971
Kishimoto, K., Medina, G., Sotelo, F., Raymundo, C.: Application of lean manufacturing techniques to increase on-time deliveries: case study of a metalworking company with a make-to-order environment in Peru. In: Ahram, T., Taiar, R., Colson, S., Choplin, A. (eds.) IHIET 2019. AISC, vol. 1018, pp. 952–958. Springer, Cham (2020). https://doi.org/10.1007/978-3-030-25629-6_148
Chiaini, A.: Improvement of OEE performance using a Lean Six Sigma approach: an Italian manufacturing case study. Int. J. Prod. Qual. Manage. 16, 416–433 (2015)
Rosa, C., Silva, F.J.G., Ferreira, L.P., Campilho, R.: SMED methodology: the reduction of setup times for Steel Wire-Rope assembly lines in the automotive industry. Procedia Manuf. 13, 1034–1042 (2017). https://doi.org/10.1016/j.promfg.2017.09.110
Bevilacqua, M., Ciarapica, F., De Sanctis, I., et al.: A Changeover Time Reduction through an integration of lean practices: a case study from pharmaceutical sector. Assembly Autom. 35(1), 22–34 (2015). https://doi.org/10.1108/AA-05-2014-035
Shingo, S.: A Revolution in Manufacturing: The SMED System. CRC Press, Boca Raton (1985)
Ahmad, R., Soberi, M.S.F.: Changeover process improvement based on modified SMED method and other process improvement tools application: an improvement project of 5-axis CNC machine operation in advanced composite manufacturing industry. Int. J. Adv. Manuf. Technol. 94(1), 433–450 (2017). https://doi.org/10.1007/s00170-017-0827-7
Díaz-Reza, J., García-Alcaraz, J., Martínez-Loya, V., Blanco, J., Jiménez, E., Avelar-Sosa, L.: The effect of SMED on benefits gained in maquiladora industry. Sustainability 8, 1237 (2016)
Reyes, S., Jeampiere, A., Castro, S., Fernanda, R.: Application of lean techniques to reduce preparation times: case study of a Peruvian plastic company. Int. J. Appl. Eng. Res. 12(23), 12 (2017)
Johnson, A., Prasad, S., Sharma, A.K.: Manufacturing lead time reduction in a scaffold making industry using lean manufacturing techniques–a case study. Int. J. Mech. Eng. Technol. 8(2), 12 (2017)
Puvanasvaran, A.P., Ab. Hamid, M.N.H., Yoong, S.S.: Cycle time reduction for coil setup process through standard work case study in ceramic industry. ARPN J. Eng. Appl. Sci. 13(1), 210–220 (2018)
Author information
Authors and Affiliations
Corresponding author
Editor information
Editors and Affiliations
Rights and permissions
Copyright information
© 2021 The Editor(s) (if applicable) and The Author(s), under exclusive license to Springer Nature Switzerland AG
About this paper
Cite this paper
Lora-Soto, A., Morales-Silva, C., Llontop-Jesus, J., Mamani, N. (2021). Process Improvement Proposal for the Reduction of Machine Setup Time in a Copper Transformation Company Using Lean Manufacturing Tools. In: Ahram, T., Taiar, R., Langlois, K., Choplin, A. (eds) Human Interaction, Emerging Technologies and Future Applications III. IHIET 2020. Advances in Intelligent Systems and Computing, vol 1253. Springer, Cham. https://doi.org/10.1007/978-3-030-55307-4_89
Download citation
DOI: https://doi.org/10.1007/978-3-030-55307-4_89
Published:
Publisher Name: Springer, Cham
Print ISBN: 978-3-030-55306-7
Online ISBN: 978-3-030-55307-4
eBook Packages: EngineeringEngineering (R0)