SMED: for quick changeovers in foundry SMEs

Abstract Purpose – The purpose of this paper is to uncover the significance of quick changeovers in die‐casting foundry environments. Design/methodology/approach – The paper gives set‐up instructions and guidelines to prepare the standardized set‐up procedure without ignoring actual constraints in foundries. It uses a case study in a medium scale piston foundry to generate an integrated set‐up reduction approach, utilizing single minute exchange of die (SMED)‐based industrial engineering tools to achieve faster set‐ups. It describes the feasibility of quick changeovers in foundry small and medium enterprises based on a "SMED" approach. Finally, the paper carries out empirical analysis of the financial/non‐financial benefits incurred from set‐up reductions. Findings – Set‐up activities are a vital part of the production lead‐time of any product and so affect overall product cost. Tools like Pareto analysis, root‐cause analysis and method study have been used to analyze the existing procedure of set‐ups. A SMED approach can help eliminate unwanted activities, externalize the internal activities, if possible and reduce them by simplification or standardization. The application of other tools such as 5S, Poke‐Yoke and specific tool‐kits are suggested to further reduce set‐up times. Originality/value – The paper demonstrates the practical application of SMED showing how it can bring real breakthroughs in productivity to small and medium scale foundries.