![]() ![]() ![]() A large-scale industry can either install multiple individual production lines to cater to the demand (usually expensive) or make frequent machinery changes. A changeover is usually required when a single machine produces different products based on the requirement. This leads to frequent changeovers and downtime. Manufacturing in smaller batches can keep the supply chain lean and customizable. Lean/six sigma tools can help companies increase production efficiency and stay in competition. Manufacturers need to find new and innovative ways to increase efficiency and reduce waste in the manufacturing supply chain. Globalization has led to a significant effect on today’s manufacturing sector. As evidenced in analytical data, it is believed that this new framework can strengthen the total output in the manufacturing process, especially in the manufacturing of automotive stamping parts. The result shows that the daily production output has increased gradually from 1100 pieces to 1500 pieces, further increasing to 2145 pieces. It shows that the proposed method decreased the changeovers processes from the initial of 1509.5 seconds to 750.75 seconds, then further reduced to 569.75 seconds, with the nett time reduction of 62.2%. The framework combined single minute exchange of die (SMED), lean tools and simulation to become an integrated single minute exchange of die (ISMED). Using a systematic dies changeover process, a new alternative framework was proposed. These simulated output data have later been compared to the actual industrial data. The study was conducted in two stages the first is on data collection correlates with the automotive stamping premise to create a simulation procedure, and the second is to analyse the current production output using WITNESS simulation. Therefore, this research aims to establish a new framework that can optimise the efficiency of the dies changeover process, which could lower the overall production cost, which could partially transfer the saving to the consumers. The most significant direct impact on this situation is the increase in operating costs due to additional time taken to meet the planned production output. ![]() The main issue observed and evidenced in data collected from industry players is that an unacceptably long time is taken in the die/tooling change process, which grossly affects the planned production output. This research is focusing on the production performance of the stamping process in Malaysia’s automotive industry. The demand for vehicles keeps increasing over time, mainly influenced by technology’s sophistication and impressive designs. The automotive industry is one of the most advanced industries in the world. ![]()
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January 2023
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