Smed-Taguchi method based order ranking approach in reduction total changeover time

Changeover time is one of the most important loss types for manufacturing companies. SMED methodology is a lean manufacturing tool used to reduce the setting times. In SMED applications, it focuses on unit setup time. However, it does not focus on the setup process factors and the order of overall production. The aim of this study is to create a hybrid method combining SMED methodology and ignored factors in order to reduce total setup time. For the application, the cold drawing line of a steel manufacturing company was selected. SMED, Taguchi and order sorting techniques were applied together on the cold drawn production line. At the beginning of the study, SMED method was used to reduce unit setup times. In the continuation of SMED application, Taguchi Experimental Design method was used to determine the factors affecting the setup time, to analyze and to reduce the factor effects. ANOVA test was applied after Taguchi Experimental Desingn. According to the ANOVA test results, it was concluded that all of the factors determined affect the setup time (p<0,05). After SMED and Taguchi methods, prioritization rules are set for order ordering. Six prioritization rules have been determined. The ordering of the rules within itself has been tried by creating alternative rankings depending on the experience and the ideal prioritization ranking has been obtained. According to the established rules, the one-month order program is listed in the EXCEL program and evaluated with the current order sorting. The total setup time in one month production plan was reduced to 1296 minutes with traditional SMED application and 1080 minutes with SMED and Taguchi application. According to the SMED Taguchi based job sequence, the total setup time is reduced to 826 minutes. The hybrid method proposed in this study has been concluded that it will contribute more to production efficiency compared to conventional SMED method.