METHODOLOGY TO MAXIMIZE ZERO LOSSES THROUGH SMED IN FOOD INDUSTRY

Abstract

The application of SMED (Single Minute Exchange of Die) gives rise to more than just reduced machinery changeover times. Correct application of SMED also reduces other types of losses which occur in the workplace and which all companies consider highly significant because of the industrial and social context in which they operate. The proposed methodology integrates prior analysis of both machinery and process, analysis and structuring of tasks, the expertise of personnel involved in applying SMED, tools that support SMED, KPI/KAI (Key Performance Indicator/Key Activities Indicator) analysis systems and standardisation. This will enable reductions in other workplace losses, such as occupational accidents and process defects that can lead to poor-quality products, as well as continuous monitoring of the machinery to reduce the number of breakdowns, etc. This article shows that the application of SMED brings discipline, task analysis, and a better understanding of machinery and worker expertise, at the same time helping to improve behaviours - indispensable aspects when seeking improvements. Usage of the performance indicators set out has been the key to demonstrating that if workplace accidents and manufacturing costs are decreased, the quality of the manufactured product is increased. Keywords: SMED; Zero losses; 5 Whys, Breakdown Analysis; Twelve Steps