Setup Time Reduction in a Reciprocating Compressor Manufacturing Company: Lean Culture for Sustainable Development and Competitiveness

Abstract

Each month, the compressor production case study business produced fewer housing components than anticipated. The data gathered showed that the production changeover time for AE compressor housing was 4,733 seconds (or around 1.3147 hours per model change), which seemed to be a longer timeframe. This study's objective was to use the single minute exchange of dies (SMED) methodology from the lean concept to shorten the time needed for the housing manufacturing of AE compressor types. This study suggested the following key solutions as useful guidelines: moving as much work from internal to external as possible; creating a suitable screw fastening clamp (i.e., an M24 t-slot bolt) to facilitate and simplify work; and designing die stoppers to help with locating the die. A 61.86% shorter changeover time now exists.