Implementasi Sistem Single Minutes Exchange of Dies untuk Perbaikan Setup Time pada Perusahaan Otomotif

Yulinda Uswatun Kasanah; Pratya Poeri Suryadhini

doi:10.56211/factory.v4i3.1407

Authors

Yulinda Uswatun Kasanah Univeritas Telkom
Pratya Poeri Suryadhini Universitas Telkom

DOI:

https://doi.org/10.56211/factory.v4i3.1407

Keywords:

Eksternal Setup; Internal Setup; Manufacturing Excellence; Parallel Setup; Setup Time Mesin; SMED

Abstract

Efisiensi proses setup merupakan faktor krusial dalam meningkatkan produktivitas dan fleksibilitas sistem produksi, terutama pada industri otomotif yang memiliki kebutuhan responsivitas tinggi terhadap variasi permintaan. Penelitian ini bertujuan untuk menganalisis dan mengurangi setup time pada workstation curing melalui penerapan metode Single Minute Exchange of Die (SMED). Metode penelitian meliputi pengamatan langsung, time study, analisis aktivitas internal dan eksternal, serta identifikasi pemborosan menggunakan prinsip lean manufacturing. Setelah kondisi eksisting dipetakan, langkah-langkah SMED diterapkan, termasuk pemisahan aktivitas internal–eksternal, konversi aktivitas internal menjadi eksternal, serta penyederhanaan dan standardisasi proses setup. Hasil penelitian menunjukkan bahwa implementasi SMED mampu mereduksi internal setup time sebesar 128,48 menit dan external setup time sebesar 3,08 menit. Reduksi signifikan diperoleh melalui konversi aktivitas seperti green tire setup dan melakukan proses pemanasan mold awal, serta persiapan peralatan yang berkontribusi terhadap penghematan waktu sebesar 63,8 menit. Selain itu, optimalisasi proses dilakukan melalui minimisasi perpindahan operator, eliminasi adjustment yang tidak diperlukan, serta penerapan parallel setup dengan menambah asisten operator, masing-masing memberikan pengurangan waktu 3,08 menit, 4,32 menit, dan 66,64 menit. Secara keseluruhan, penelitian ini membuktikan bahwa integrasi SMED pada proses curing tidak hanya menurunkan waktu non-productive secara substansial mencapai 33,77%, tetapi juga meningkatkan kelancaran aliran produksi dan mendukung pencapaian manufacturing excellence.

Downloads

Download data is not yet available.

References

[1] P. E. Dossou, G. Laouénan, and J. Y. Didier, “Development of a Sustainable Industry 4.0 Approach for Increasing the Performance of SMEs,” Processes, vol. 10, no. 6, Jun. 2022, doi: 10.3390/pr10061092.

[2] S. Boran and C. Ekincioğlu, “A novel integrated SMED approach for reducing setup time,” International Journal of Advanced Manufacturing Technology, vol. 92, no. 9–12, pp. 3941–3951, Oct. 2017, doi: 10.1007/s00170-017-0424-9.

[3] J. Singh, H. Singh, and I. Singh, “SMED for quick changeover in manufacturing industry – a case study,” Benchmarking, vol. 25, no. 7, pp. 2065–2088, Oct. 2018, doi: 10.1108/BIJ-05-2017-0122.

[4] S. C. Nwanya, J. I. Udofia, and O. O. Ajayi, “Optimization of machine downtime in the plastic manufacturing,” Cogent Eng, vol. 4, no. 1, Jan. 2017, doi: 10.1080/23311916.2017.1335444.

[5] P. B. Patel, “Optimizing Plant Performance through Breakdown-Based Downtime Analysis,” International Journal of Research and Analytical Reviews, 2023, [Online]. Available: www.ijrar.org

[6] L. Jurík, N. Horňáková, and V. Domčeková, “The application of smed method in the industrial enterprise,” Acta Logistica, vol. 7, no. 4, pp. 269–281, 2020, doi: 10.22306/al.v7i4.189.

[7] V. Parwani and G. Hu, “Improving Manufacturing Supply Chain by Integrating SMED and Production Scheduling,” Logistics, vol. 5, no. 1, Mar. 2021, doi: 10.3390/logistics5010004.

[8] F. Sumasto, M. A. Arrofah, I. R. Pratama, S. P. Purbaningrum, A. Satria, and A. Rapi, “Application of Single Minute Exchange Die (SMED) Method to Minimize Setup Time on 350T Capacity Molding Machine,” Jurnal Inotera, vol. 10, no. 1, pp. 33–40, Jan. 2025, doi: 10.31572/inotera.vol10.iss1.2025.id422.

[9] R. Godina, C. Pimentel, F. J. G. Silva, and J. C. O. Matias, “A Structural Literature Review of the Single Minute Exchange of Die: The Latest Trends,” in Procedia Manufacturing, Elsevier B.V., 2018, pp. 783–790. doi: 10.1016/j.promfg.2018.10.129.

[10] F. Sumasto, M. A. Arrofah, I. R. Pratama, S. P. Purbaningrum, A. Satria, and A. Rapi, “Application of Single Minute Exchange Die (SMED) Method to Minimize Setup Time on 350T Capacity Molding Machine,” Jurnal Inotera, vol. 10, no. 1, pp. 33–40, Jan. 2025, doi: 10.31572/inotera.vol10.iss1.2025.id422.

[11] M. Kemal Karasu, M. Cakmakci, M. B. Cakiroglu, E. Ayva, and N. Demirel-Ortabas, “Improvement of changeover times via Taguchi empowered SMED/case study on injection molding production,” Measurement (Lond), vol. 47, no. 1, pp. 741–748, 2014, doi: 10.1016/j.measurement.2013.09.035.

[12] J. Filla, “The single minute exchange of die methodology in a high-mix processing line,” Journal of Competitiveness, vol. 8, no. 2, pp. 59–69, Jun. 2016, doi: 10.7441/joc.2016.02.05.

[13] M. Kemal Karasu, M. Cakmakci, M. B. Cakiroglu, E. Ayva, and N. Demirel-Ortabas, “Improvement of changeover times via Taguchi empowered SMED/case study on injection molding production,” Measurement (Lond), vol. 47, no. 1, pp. 741–748, 2014, doi: 10.1016/j.measurement.2013.09.035.

[14] S. Shingo, A Revolution in Manufacturing: The SMED System. Taylor & Francis, 2019.

[15] A. A. Karam, M. Liviu, V. Cristina, and H. Radu, “The contribution of lean manufacturing tools to changeover time decrease in the pharmaceutical industry. A SMED project,” in Procedia Manufacturing, Elsevier B.V., 2018, pp. 886–892. doi: 10.1016/j.promfg.2018.03.125.

[16] G. F. I. Toki et al., “Single Minute Exchange Die (SMED): A sustainable and well-timed approach for Bangladeshi garments industry,” Clean Eng Technol, vol. 12, Feb. 2023, doi: 10.1016/j.clet.2022.100592.

[17] T. Aprianto, A. Nuryono, and I. Setiawan, “Waste Analysis in the Speaker Box Assy Process to Reduce Lead Time in the Electronic Musical Instrument Industry,” 2022.

[18] S. P. R. Haris, T. D. Sofianti, and A. T. Pratama, “Penerapan Pendekatan SMED untuk Mengurangi Waktu Pergantian dalam Proses Pengujian di Perusahaan Listrik Multinasional,” Jurnal Media Teknik dan Sistem Industri, vol. 9, no. 1, p. 47, Mar. 2025, doi: 10.35194/jmtsi.v9i1.4346.