Research On Improvement Of Exchanging Die Programme In Casting Workshop Of Company S

With the development of the modern society, the requirement to personality of people is becoming increasingly high. This phenomenon causes the trend that manufacturing companies’ order becomes more complicated and the product mix become high and the volume becomes low. This trend leads to longer changeover time to manufacturing companies. How to reduce the machine changeover time,especially internal changeover time is a problem to manufacturing enterprises for improving the competitiveness of enterprises.According to experiences in company S as an intern, combined with modern lean production management and SMED theory, the writer uses process diagrams and value stream mapping to analyze Casting workshop characteristics of production systems in company S. And the writer finds that changeover time is so long in Casting workshop. Based on analysis of the existing detailed changeover program,the writer finds three main problems. The first one is there is no obvious distinction between internal changeover time and external changeover time; the second one is the external changeover is not so fully prepared that internal changeover time is so long; the last one is changeover operations are not standardized. In order to find a solution to solve these problems, I use SMED method(work study、5W1H method and ECRS principles) to distinguish internal and external changeover time. In addition, I analyze the existing internal changeover time by using process flow diagram to find out wasted time. I take measures to make the internal changeover time shift to external changeover time, and take the double joint operation method to shorten the internal changeover time. The internal changeover time is reduced by24.6%. At last, I use SOP method to make the changeover operations standard.The actual result of this case study provides the basis for multi variety and small batch production enterprises on reducing internal changeover time..