25-08-2017, 09:32 PM
SINGLE MINUTE EXCHANGE OF DIE
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INTRODUCTION:
The JBM Group, under the name of Jay Bharat Maruti Ltd., entered into a joint venture with Maruti Suzuki and a largest venture emerged in 1987. The joint venture since then is engaged in world class manufacturing through indigenous press lines, robotic welding besides plating and painting facilities.
The venture keeping pace with time and technology extended its capacities in 1991 and then in 1993. In the year 1995, a new plant was setup, which further developed and extended in 1996, 2001 and 2002.
The venture further added modern capacities in the production of exhaust systems, axles and fuel neck fillers to existing steel metal components and welded modules.
The JBM’s endeavors to attain new technology and excel in every field, it ventured into, received acclimation and recognition in its consumer circles and apex bodies like CII EXIM Bank, ACMA, SIAM and NPC.
MAIN ACTIVITIES AND PRODUCTS
PRESS LINE
The sheet metal components manufacturing capability at JBML, consisting of world-class press lines like a fully automatic tandem line, hydraulic and mechanical single action and double action from renowned international manufacturers like, Rovetta, Hitachi, ISGEC and HMT give JBML a distinct advantage. What enhances this edge is the ability to deliver on ‘Just in sequence’ basis. The critical die maintenance facilities that support the press line include die-spotting presser from Kojima and Muller, a state of the art tool room and skilled and trained manpower.
WELD SHOP
Weld shop comprising of contemporary equipment and highly versatile machines from the heart of JBML`s fabrications operations. Geared for complex welding operations, these gigantic weld shops utilize an array of modern gadgets like stationary spot welding with nut feeders, portable spot weld, seam welding, MIG/TIG welding submerged are welding and SPMs. JBML`s highly developed skills in welding operations contributes significantly to superior quality and reliability of the end product, which is the hallmark of JBML.
FLEXIBLE MANUFACTURING SYSTEMS
To provide complete customer solutions, JBML uses a flexible manufacturing system (FMS), to plan and develop a large quantity of components with varying volumes in an amazing short time. The five axes laser-cutting machines from the premier global manufacturer, Prima of Italy, given JBML a cutting edge. With this, no trimming, blanking or piercing tools are required. In other words, this leads to tremendous cost savings, and cuts down a great deal of lead-time in manufacturing.
EXHAUST SYSTEM
A complex automobile exhaust system is another area where JBML has demonstrated exceptional competence. Today, JBML is an excellent source for two and four wheeler exhaust systems in the country and a major OE supplier. The manufacturing of exhaust systems incorporating new designs and development needs elaborate facilities. At, JBML, these facilities includes welding robots, curling, seaming, flanging and seam welding machines, CNC pipe bending machines, double coiling with multi spot welding SPMs, baffle assembly stations, shot blasting and electrostatic painting equipments. In a short period, JBML has created a name for itself in flawless and effective exhaust systems.
QUALITY IS COMPONENT NO. 1
More than anything else the driving force at JBML is “quality’. Stringent quality control maintained at every stage of the designing and manufacturing process translates into zero defects, international standard products. Rotted in the policy to achieve total customer satisfaction by delivering product and service that meet and exceed their expectations, on time and at competitive cost. JBML has developed a tradition of quality. Every personnel is positively attuned and committed to excellence. It is a corporate motto at JBM to accomplish tasks right the first time, every time. And ongoing improvement on manufacturing processes and advanced quality planning play a critical role in ensuring high standard. No wonder, globally JBML became the first company to achieve ISO/TS-16949- 2002 certification. Also, concern for environment protection has brought JBML ISO- 14000 certification.
SINGLE- MINUTE EXCHANGE OF DIE
(SMED)
Introduction
SMED is the term used to represent the Single Minute Exchange of Die or setup time that can be counted in a single digit of minutes. SMED is often used interchangeably with “quick changeover”. SMED and quick changeover are the practice of reducing the time it takes to change a line or machine from running one product to the next. The need for SMED and quick changeover programs is more popular now than ever due to increased demand for product variability, reduced product life cycles and the need to significantly reduce inventories.
As the name suggests, SMED is the process involving steps towards changing of the die(of any given profile) after a requisite amount of batches are produced during a work scheduled.
In order to obtain an "economic order quantity" during a manufacturing scheduled it becomes important that our allowance time such as die exchange should be reduced in order to restart our manufacturing work in minimum time which is both practical(in terms of labour force time required to change the die) and economical feasability also.Therefore,the thrust remains upon ensuring steps to reduce die exchange time.
To understand how SMED can help we have to look at the changeover process. Typically when the last product of a run has been made the equipment is shut down and locked out, the line is cleaned, tooling is removed or adjusted, new tooling may be installed to accommodate the next scheduled product. Adjustments are made, critical values are met (die temperature, accumulators filled, hoppers loaded, etc.) and eventually the startup process begins – running product while performing a time, time that can be reduced through SMED.
HISTORY OF SMED
The concept arose in the late 1950s and early 1960s, when Shigeo Shingo was consulting to a variety of companies including Toyota, and was contemplating their inability to eliminate bottlenecks at car body-moulding presses. The bottlenecks were caused by long tool changeover times which drove up production lot sizes. The economic lot size is calculated from the ratio of actual production time and the 'change-over' time; which is the time taken to stop production of a product and start production of the same, or another, product. If change-over takes a long time then the lost production due to change-overs drives up the cost of the actual production itself. This can be seen from the table below where the change-over and processing time per unit are held constant whilst the lot size is changed. The Operation time is the unit processing time with the overhead of the change-over included. The Ratio is the percentage increase in effective operating time caused by the change-over. SMED is the key to manufacturing flexibility.