Set-up reduction in injection molding process- A case study in packaging industry

Abstract

The competitiveness of manufacturers can be significantly enhanced through implementation of Setup Reduction (SUR) initiatives. This paper presents a simplified SUR approach which was trialed and fully implemented in an injection molding facility. The identification of bottlenecks in production was carried out by using extensive data gathering on machine down-time and/or changeover time records. The detailed analysis of the operations carried out by employees were investigated by using the Single Minute Exchange of Dies (SMED) philosophy. Close collaboration with employees and formation of SUR teams facilitated the development of a system for the organization and storage of molds. The system developed ensures mold readiness conditions, reduces lead times and improves the storage, monitoring and accessibility of machine programs.