The use of Quality Tools to support a SMED implementation

Purpose – This work discusses a SMED implementation carried out in the assembly department of a sanitary components’ factory, located in Aveiro, Portugal, with the support of quality tools. The case study focused on the process of changing production codes, for cistern structures manufacturing cells.
Methodology – The first step of the study was the development of a SIPOC diagram to represent the production process. The next step was to identify the tasks required by the setup, whenever a new production order starts. The data needed to define and analyze the initial state of the setup was collected on the shop floor, which helped to identify problems and opportunities for improvement. The relevance and causes of the problems were explored using quality tools such as a Pareto Chart and an Ishikawa Diagram, and then improvement actions were proposed and implemented. To standardize the setup, a procedure was defined, which required the use of additional quality tools, namely 5Whys, 5S and Kamishibai.
Findings – The implementation of these actions resulted in an 18% reduction in the average time of the setup. There is also a positive balance in terms of the standardization of processes and the maintenance of tools and equipment, which are crucial in ensuring that no waiting and no inappropriate or extraneous activities occur during setup.
Originality/value – This work showed how quality tools can be integrated in a SMED process,
assisting in identifying improvement opportunities and in involving workers in the process, which leads to more lasting results

SMED, Quality Tools, Continuous Improvement