Application of single minute exchange of die lean method in improving productivity: Study of an injection molding process

This paper investigates reduction in work-in-process inventory by implementing Single-Minute Exchange of die technique and Kanban System in injection molding process of automotive parts manufacturing organization. Data was collected regarding setup time for most voluminous produced emblem, recognition of tasks involved in method of change over, finding and removing unnecessary internal activities and standardizing the modified process through Kanban implementation. Findings indicated that after SMED implementation setup-time was cut by 53% and 25 minutes per set up were saved implying saving of total 750 minutes of production time per month which is almost equivalent to improvement in 2% productivity. Daily production quantity was reduced by 25% and WIP stock of injection molding process was reduced by 50%. Demonstration of application of SMED in an automobile parts company showing real time reduction in inventory and productivity improvement was core of this paper. The results can apply to other intermediate component manufacturers to have wider beneficial implications for the entire supply chain.