Aladdin365’s Post

What Is SMED ? SMED (Single-Minute Exchange of Dies) is a lean manufacturing methodology designed to minimize the time required to switch from one process or product to another. It focuses on reducing setup times in production, making processes more efficient and flexible. Key Principles of SMED ? Separate Internal and External Activities: Internal activities: Tasks that can only be done when the machine or process is stopped. External activities: Tasks that can be done while the machine or process is running (e.g., preparing tools). Convert Internal to External Activities Reducing downtime by preparing as much as possible in advance. Streamline Remaining Internal Activities: Simplify and standardize tasks to make them faster and more efficient. Eliminate Non-Value-Adding Activities: Remove unnecessary steps or delays Importance of SMED for Chemical Industries Reduced Downtime Chemical processes often involve lengthy setups for equipment and process adjustments. SMED minimizes downtime, allowing for quicker transitions between products or batches. Improved Flexibility The chemical industry often deals with small batch sizes, custom formulations, or seasonal demand. SMED enables faster changes, making operations more adaptable to market needs. Enhanced Productivity By reducing setup times, machines and equipment can operate for longer durations, increasing overall throughput. Cost Savings Shorter setup times mean lower labor and energy costs. It also reduces the need for excess inventory, as production can align more closely with demand. Reduced Waste Faster setups reduce the chances of errors, off-spec products, and raw material waste during transitions. Regulatory Compliance In chemical industries, setups often involve cleaning, safety checks, and documentation. Streamlining these processes ensures faster compliance with strict industry regulations. Increased Equipment Utilization Optimizing setups maximize the productive use of expensive chemical processing equipment. By implementing SMED, chemical industries can achieve greater efficiency, respond faster to customer needs, and maintain a competitive edge in the market. #SMED#TQM

What are the principles of lean manufacturing? Learn all about lean manufacturing and how D&M Plastics implements lean principles to better serve our customers: https://lnkd.in/gs6V2Van #plastics #plasticinjectionmolding #manufacturing

We recently published the first in a series of blog posts addressing the eight costly wastes identified with the acronym DOWNTIME. Lean manufacturing practitioners specify the first form of waste is DEFECTS waste. It can cost you much more than just the labor and materials of fixing defective product. Learn more about this here >> https://lnkd.in/g-sz4Deu

To identify and minimize waste from different processes is a key aspect of lean manufacturing implementation. Review attached basic understanding of waste and practical examples of each waste. https://lnkd.in/dPw6wbs2

Maximizing profit and minimizing resource usage are key goals for any manufacturing company. It's time to improve your manufacturing processes– find out how! ⤵️ #kbdelta #manufacturing #manufacturingefficiency

From concept to solution. We designed this unit to align materials through the production process. As materials exit this unit, they will hit a conveyor belt to move to the next step, which eliminates the need for a person to stand there and transfer each piece manually. Creating solutions for better manufacturing! Have a bottleneck or efficiency problem and need some guidance? Give us a call and let us provide some options.

Quality is Free! A Manufacturing Case Study Cutting Scrap Costs and Minimizing Variations in Polypropylene Extrusion Discover how one facility tackled process variations and high scrap costs using Six Sigma and Lean principles. Challenge: A polypropylene extrusion facility with 13 extrusion lines struggled with significant process variations, particularly during startup phases. One line, contributing nearly 30% of the plant’s total output, was also responsible for around 740,000 pounds of scrap material annually—almost 30% of the facility's total scrap. The high scrap levels highlighted a critical need to minimize startup process variation and improve overall yield. Objective: The facility set an ambitious target: reduce the scrap ratio on the primary extrusion line from an average of 1.19% to 0.60%. This would not only enhance productivity but also significantly lower the Cost of Quality. Key Improvements: The team focused on minimizing process variations, particularly during the startup phase, which was identified as a significant contributor to scrap generation. - Minimizing Startup Variations: Streamlined the startup process to reduce fluctuations that lead to defects. - Lean and Six Sigma Integration: Combined Lean principles to eliminate waste with Six Sigma tools to reduce process variability. - Enhanced Process Controls: Introduced tighter controls on critical process parameters to stabilize production and improve yield. - Operator Training: Focused on educating operators about minimizing variations during startup and adhering to best practices for quality. Results: The integrated approach led to a 55% reduction in scrap on the main extrusion line, resulting in an annual cost savings of over $300,000. The focus on minimizing startup process variation not only improved yield but also demonstrated how combining Lean and Six Sigma can drastically lower the Cost of Quality. Quality is Free! This success story highlights the importance of Quality and how it can reduce costs, thereby providing a positive return on investment. What strategies have you used to reduce process variation and scrap in your operationsHow do you approach reducing the Cost of Quality in your processes? What's your approach to investments in quality? Comment below—we’d love to hear your experiences! #Quality #PDCA #Lean

𝗕𝗿𝗶𝗲𝗳𝗹𝘆 6! 💡 Many may confuse between production and manufacturing. So let's clarify the finer points. 👇 Production is about transforming inputs or intermediates into final outputs, results in the provision of good and services, and may or may not involve the use of machinery. Meanwhile, manufacturing results exclusively in goods, and it is by transforming raw material into finished goods. Tip 💡: Every production is not manufacturing, but every manufacturing is production.

Implementing the 5S methodology is crucial for plastic processing industries to minimize mistakes and avoid time loss. We strongly recommend that medium-scale and large-scale manufacturers adopt centralized material conveying systems and plant automation. This helps address common issues such as: • Mixing of raw materials • Loss of time • Loss of production • Spillage of raw materials • Accidents resulting from raw material spillage Additionally, a well-organized plant not only enhances operational efficiency but also instills confidence in customers, making them more likely to engage in business with you.

What is waste ? What is the Waste of Lean manufacturing ? "Waste” is any action or activity that does not add value to the Product/Process/ Service/ System. Essentially, "waste" is any unnecessary step in a manufacturing process that does not benefit the customer, therefore, the customer does not want to pay for it. The wastes of lean manufacturing are eight types of activities that reduce efficiency and can be eliminated to improve a business's bottom line. These wastes are often referred to as TIMWOODS, an acronym that's easy to remember and helps identify areas for improvement.    Lean is a philosophy that aims to optimize resource use by eliminating waste.  To achieve operational excellence, lean principles need to be continuously assessed and refined. According to the Lean, Manufacturing system, The 8 waste are :- Transportation: Moving materials or products when it's not necessary can lead to delays and damage    Inventory: Stockpiling items takes up space and ties up capital    Motion: Unnecessary or excessive movement of people can lead to fatigue and errors    Waiting: When production lines or workers are idle, it's a waste of time and resources    Overproduction: Making more than what's needed leads to surplus inventory and higher costs    Overprocessing: Doing more than what's required adds unnecessary costs and complexity    Defects: Any flaws or mistakes in the process result in rework and wasted resources    Non-utilized talent/Skills: Not using employees' skills, creativity, or potential contributions.