%0 Journal Article
%T Measurement of Overall Performance Effectiveness in Setup Improvement
%A Shye-Nee Low
%A Siu-Hou Chong
%A Hui-Yee Sim
%A Solehhudin Razalli
%A Shahrul Kamaruddin
%J Journal of Industrial Engineering
%D 2014
%I Hindawi Publishing Corporation
%R 10.1155/2014/264980
%X This study aimed to improve the setup process of injection molding machines by using the developed setup improvement methodology. Overall performance effectiveness (OPE) was used to evaluate the setup improvement. A case study was tested on the application of the developed setup improvement methodology. A 50.1% reduction in setup time was attained by the developed methodology, and significant time savings were achieved with minimum investment. Comparisons between before and after improvement implementation were conducted through OPE to verify the improvement. In terms of OPE, the setup performance in the case study considered an acceptable value of 60.45%. The setup process performance of the developed setup improvement methodology was judged in terms of effectiveness. Results therefore indicate that OPE measurement is an effective way to analyze the efficiency of a single setup process. 1. Introduction Customer demands with low volume but high variety are often highly volatile because of the growing dynamics of today¡¯s market. Low-volume production for a high variety of goods reveals to companies the necessity of improving their changeover or setup performance to provide quick response to customer demands. Van Goubergen and Van Landeghem [1] argued that setup reduction is important as it can significantly affect production time to increase production throughput. Single-minute exchange of die (SMED) is a setup reduction concept introduced by Shigeo Shingo in the 1950s to improve productivity by improving setup operations. SMED is used as one of the elements in a continuous improvement process [2]. For instance, Patel et al. [3] developed a new structured methodology based on lean SMED and mistake proofing methods to improve the changeover process in the machining of precision components for the aerospace industry in a more efficient manner as well as to redesign these activities to make the convertibility process less timely by using simple poka-yoke devices. Cakmakci and Karasu [4] used a predetermined time system to standardize setup operations according to a set of standard operation procedures in the automobile industry. The integration of a predetermined time system and SMED yields a better improvement of setup operations based on a detailed motion study of setup activities. Moreira and Pais [5] showed that SMED is an excellent concept for improving setup operations in the mold-making industry. SMED implementation allowed the authors to identify the key drivers to productivity improvement and to improve setup operations by reducing waste
%U http://www.hindawi.com/journals/jie/2014/264980/