Setup Time Measurement on Flexo 4 Using The Single-Minute Exchange of Dies (SMED) Method in a Multi-Group Cardboard Production Setting
DOI:
https://doi.org/10.31004/jutin.v8i2.44790Keywords:
Machine Setup, Single-Minute Exchange of Dies (SMED), Flexo MachineAbstract
Long and unstandardized setup times are a major source of inefficiency in the cardboard packaging production process, particularly on the Flexo 4 machine, which requires 1.5 to 2 hours for setup. This study aims to reduce setup time by implementing the SMED (Single-Minute Exchange of Dies) method. Three internal activities—ink retrieval, material preparation, and plate preparation—were converted into external activities, reducing setup time by up to 66.67%. Observations were made on three work groups during shift 1, with average setup times ranging from the longest to the shortest: Group C (33.9 minutes), Group A (32.3 minutes), and Group B (30.05 minutes). ANOVA results show no significant differences between the groups. The longest setup time occurred in Group C, with 7,500 pcs and 4 plates, taking 75 minutes. This was due to the Mounting Plate process and limited operator resources.References
Ahmad, A., JK, H., & Yonathan, A. (2021). Meminimasi Pemborosan dengan Lean Manufacturing pada Proses Produksi di PT. IE. Prosiding SENAPENMAS. https://doi.org/10.24912/psenapenmas.v0i0.15217
Andri, A., & Sembiring, D. (2019). Penerapan Lean Manufacturing Dengan Metode VSM (Value Sream Mapping) untuk Mengurangi Waste Pada Proses Produksi Pt.XYZ. Faktor Exacta, 11(4). https://doi.org/10.30998/faktorexacta.v11i4.2888
Ani, M. N. bin C., & Shafei, M. S. S. bin. (2013). The effectiveness of the single minute exchange of die (SMED) technique for the productivity improvement. Applied Mechanics and Materials, 465–466. https://doi.org/10.4028/www.scientific.net/AMM.465-466.1144
Dharmayanti, I., & Marliansyah, H. (2019). Perhitungan Efektivitas Lintasan Produksi Menggunakan Metode Line Balancing. Jurnal Manajemen Industri Dan Logistik, 3(1). https://doi.org/10.30988/jmil.v3i1.63
Díaz-Reza, J., García-Alcaraz, J., Martínez-Loya, V., Blanco-Fernández, J., Jiménez-Macías, E., & Avelar-Sosa, L. (2016). The Effect of SMED on Benefits Gained in Maquiladora Industry. Sustainability, 8(12), 1237. https://doi.org/10.3390/su8121237
Dixit, A., Dave, V., & Singh, A. P. (2015). Lean Manufacturing: An Approach for Waste Elimination. International Journal of Engineering Research And, V4(04). https://doi.org/10.17577/IJERTV4IS040817
Gavali, R., Chavan, S., & Dongre, P. G. G. (2016). Set-up Time Reduction of a Manufacturing Line using SMED Technique. International Research Journal of Engineering and Technology, 03(07).
Harahap, N. A. P., Qadri, F. A., Harahap, D., Situmorang, M., & Wulandari, S. (2023). Analisis Perkembangan Industri Manufaktur Indonesia. Jurnal Kajian Ekonomi Dan Bisnis Islam El-Mal, 4(6), 1444–1450. https://doi.org/1047467/elmal.v416.2918
Lestari, E. P., & WSU, I. (2017). Analisis Kinerja Industri Manufaktur di Indonesia. Jurnal Riset Ekonomi Dan Manajemen, 17(1). https://doi.org/10.17970/jrem.17.170115.id
Maharani, D. A., & Musfiroh, I. (2021). Review: Penerapan Metode Single-Minute Exchange of Dies Sebagai Upaya Peningkatan Produktivitas Kerja Di Industri Farmasi. Majalah Farmasetika, 6(3), 287–299. https://doi.org/10.24198/mfarmasetika.v6i3.34884
Marcella, S., & Widjajati, E. P. (2024). Analysis of Lean Manufacturing Implementation through the Single Minute Exchange of Dies (SMED) Method to Reduce Setup Time in the Injection Molding Machine Process. Journal of Applied Science, Engineering, Technology, and Education, 6(1), 17–26. https://doi.org/10.35877/454RI.asci2698
Nee, L. S., Hou, C. S., Yee, S. H., Razalli, S., & Kamaruddin, S. (2012). External Setup in SMED Improvement in an Injection Molding Manufacturing Company. Applied Mechanics and Materials, 229–231, 2551–2555. https://doi.org/10.4028/www.scientific.net/AMM.229-231.2551
Novirani, D., Zulkarnain, F. P., & Darrent, T. (2024). Application of Lean Manufacturing to Minimize Waste in The Production Process of Tin Stabilizer. E3S Web of Conferences, 484. https://doi.org/10.1051/e3sconf/202448401002
Purnomo, E., Rachma Dwicahyani, A., & Lillahulhaq, Z. (2021). Analisa dan Perbaikan Waktu Set-up Pergantian Cetakan dengan Metode Single-Minute Exchange of Dies (SMED) (Studi Kasus: PT. XYZ). Senastitan 1.
Rahul, M. R., Joshi, & Naik, G. R. (2012). Reduction in Setup Time By SMED A Literature Review. International Journal of Modern Engineering Research (IJMER) Www.Ijmer.Com, 2(1).
Ribeiro, R. B., Souza, J. De, Beluco, A., Biehl, L. V., Braz Medeiros, J. L., Sporket, F., Rossini, E. G., & Amaral, F. A. D. Do. (2019). Application of the single-minute exchange of die system to the CNC sector of a shoe mold company. Cogent Engineering, 6(1). https://doi.org/10.1080/23311916.2019.1606376
Shinde, S., Jahagirdar, S., Sane, S., & Karandikar, V. (2014). Set-up time Reduction of a Manufacturing Line using SMED Technique. International Journal of Advance Industrial Engineering, 2(2).
Sugarindra, M., Ikhwan, M., & Suryoputro, M. R. (2019). Single Minute Exchange of Dies as The Solution on Setup Processes Optimization by Decreasing Changeover Time, A Case Study in Automotive Part Industry. IOP Conference Series: Materials Science and Engineering - Annual Conference on Industrial and System Engineering (ACISE), 012026. https://doi.org/10.1088/1757-899X/598/1/012026
Suhardi, B., & Satwikaningrum, D. (2015). Perbaikan Waktu Set Up Dengan Menggunakan Metode SMED. Seminar Nasional IENACO.
Talekar, A. A., Patil, S. Y., Shinde, P. S., & Waghmare, G. S. (2019). Setup time reduction using single minute exchange of dies (SMED) at a forging line. 020018. https://doi.org/10.1063/1.5141188
Ulutas, B. (2011). An application of SMED methodology. World Academy of Science, Engineering and Technology, 79.
Wibowo, A. D. W., & Lukmandono. (2021). Implementasi Metode Single Minute Exchange of Dies (SMED) dan Maynard Operation Sequence Technique (MOST) untuk Perbaikan Waktu Proses Produksi (Studi Kasus Departemen Produksi-Wrapping di PT. X Surabaya). Prosiding Seminar Nasional Teknologi Industri Berkelanjutan, 52–60.
Widodo, T., Fardiansyah, I., & Sunarya. (2023). Implementasi Single Minute Exchange Of Dies (Smed) Untuk Perbaikan Waktu Set-Up Pergantian Size Pada Mesin Rbg-Bg 1 di PT. GT R. Journal Industrial Manufacturing, 8(1), 41–50. https://doi.org/10.31000/jim.v8i1.8083
Yafi, M. A., Kustiwan, S., & Wiyatno, T. N. (2024). Efisiensi Waktu Change Model Injection Molding Machine Menggunakan Metode Single Minute Exchange Of Dies (SMED) di PT. XYZ. G-Tech: Jurnal Teknologi Terapan, 8(3), 1859–1868. https://doi.org/10.33379/gtech.v8i3.4610
Downloads
Published
How to Cite
Issue
Section
License
Copyright (c) 2025 Popy Dian Riyanti, Amalia Amalia
This work is licensed under a Creative Commons Attribution-ShareAlike 4.0 International License.
