A Comparison of the Application of the SMED Methodology in Two Different Cutting Lines

Alexandre Silva, José C. Sá, Gilberto Santos, Francisco J.G. Silva, Luís P. Ferreira, Maria T. Pereira


Purpose: This study was carried out in a cork company and its purpose was to observe and analyze the practices and methods used during the tools/series change moments and to propose improvements and alternatives to these same procedures so that the time needed to carry out the setup is reduced by 15% in both lines.

Methodology/Approach:The methodology included the following phases: 1st - historical data collection and setup video recording, 2nd - footage analysis and conduction of informal interviews with employees, 3rd - flow, Gantt, and spaghetti charts creation and making of an action plan based on the waste and improvement opportunities identified in video analysis, 4th - validation with the line workers of the new operating mode created with the Single Minute Exchange of Dies (SMED) tool and communication to the Maintenance department about their role in this project, 5th - making and placement of plasticized cards on the cutting lines to ensure that new operating mode is followed and carrying out the actions identified in the action plan.

Findings: Throughout this project using observations, video recording and its subsequent analysis, as well as interviews to the workers operating in the line, it was found the existence of several actions carried out by them during the setups which did not add value to the product, lack of adequate tools for the work to be performed and lack of work tools in general

Research Limitation/implication: The study was limited by the lines and products under study and by the duration of the curricular internship, which was about five months.

Originality/Value of paper: The article demonstrates the added value in terms of product quality and production output rate that SMED methodology can bring to companies that adopt the lean philosophy and in particular this continuous improvement tool.


Abdulmalek, F.A. and Rajgopal, J., 2007. Analyzing the benefits of lean manufacturing and value stream mapping via simulation: A process sector case study. International Journal of production economics, [e-journal] 107(1), pp.223-236. DOI: 10.1016/j.ijpe.2006.09.009.

Ahmad, R. and Soberi, M.S.F., 2018. Changeover process improvement based on modified SMED method and other process improvement tools application: an improvement project of 5-axis CNC machine operation in advanced composite manufacturing industry. The International Journal of Advanced Manufacturing Technology, [e-journal] 94, pp.433-450. DOI: 10.1007/s00170-017-0827-7.

Allahverdi, A. and Soroush, H.M., 2008. The significance of reducing setup times/setup costs. European Journal of Operational Research, [e-journal] 187(3), pp.978-984. DOI: 10.1016/j.ejor.2006.09.010.

Araujo, R., Santos, G., Costa, J.B. and Sá, J.C., 2019. The Quality Management System as a Driver of Organizational Culture: An Empirical Study in the Portuguese Textile Industry. Quality Innovation Prosperity, [e-journal] 23(1), pp.1-24. DOI: 10.12776/qip.v23i1.1132.

Azevedo, J., Sá, J.C., Ferreira, L.P., Santos, G., Cruz, F.M., Jimenez, G. and Silva, F.J.G., 2019. Improvement of production line in the automotive industry through lean philosophy. Procedia Manufacturing, [e-journal] 41, pp.1023-1030. DOI: 10.1016/j.promfg.2019.10.029.

Barbosa, L.C.F.M., de Oliveira, O.J. and Santos, G., 2018. Proposition for the alignment of the integrated management system (quality, environmental and safety) with the business strategy. International Journal for Quality Research [e-journal] 12(4), pp.925-940. DOI: 10.18421/IJQR12.04-09.

Berger, A., 1997. Continuous improvement and kaizen: standardization and organizational designs. Integrated manufacturing systems, [e-journal] 8(2), pp.110-117. DOI: 10.1108/09576069710165792.

Bhagwat, N.V., 2005. Balancing a U-Shaped Assembly Line by applying Nested Partitions Method. Ph.D. United States: Ames Lab., Ames, IA. DOI: 10.2172/861605.

Boran S. and Ekincioğlu, C.A., 2017. A novel integrated SMED approach for reducing setup time. The International Journal of Advanced Manufacturing Technology, [e-journal] 92, pp.3941-3951. DOI: 10.1007/s00170-017-0424-9.

Bravi, L., Murmura, F. and Santos, G., 2017. Attitudes and behaviours of Italian 3D prosumer in the Era of Additive Manufacturing. Procedia Manufacturing, [e-journal] 13, pp.980-986. DOI: 10.1016/j.promfg.2017.09.095.

Bravi, L., Murmura, F. and Santos, G., 2018. Manufacturing labs: Where new digital technologies help improve life quality. International Journal for Quality Research, [e-journal] 12(4), pp.957-974. DOI: 10.18421/IJQR12.04-11.

Bravi, L., Murmura, F. and Santos, G., 2019. The ISO 9001:2015 quality management system standard: Companies’ drivers, benefits and barriers to its implementation. Quality Innovation Prosperity, [e-journal] 23(2), pp.64-82. DOI: 10.12776/QIP.V23I2.1277.

Carvalho, F., Santos, G. and Gonçalves, J., 2019. Critical analysis of information about integrated management systems and environmental policy on the Portuguese firms' website, towards sustainable development. Corporate Social Responsibility and Environmental Management, [e-journal] 27, pp.1069-1088. DOI: 10.1002/csr.1866.

Coimbra, E.A., 2009. Total Flow Management: Achieving Excellence with Kaizen and Lean Supply Chains. Kaizen Institute.

Correia, D., Silva, F.J.G., Gouveia, R., Pereira, T. and Ferreira, L.P., 2018. Improving manual assembly lines devoted to complex electronic devices by applying Lean tools. Procedia Manufacturing, [e-journal] 17, pp.663-671. DOI: 10.1016/j.promfg.2018.10.115.

Costa, A.R., Barbosa, C., Santos, G. and Rui Alves, M., 2019. Six sigma: Main metrics and r based software for training purposes and practical industrial quality control. Quality Innovation Prosperity, [e-journal] 23(2), pp.83-100. DOI: 10.12776/QIP.V23I2.1278.

Costa, E., Bragança, S., Sousa, R. and Alves, A., 2013. Benefits from a SMED application in a punching machine. Engineering and Technology International Journal of Industrial and Manufacturing Engineering, [e-journal] 7(5), pp.1-8. DOI: 10.5281/zenodo.1088518.

Costa, M.J.R., Gouveia, R.M., Silva, F.J.G. and Campilho, R.D.S.G., 2018. How to solve quality problems by advanced fully-automated manufacturing. The International Journal of Advanced Manufacturing Technology, [e-journal] 91, pp.4043-4054. DOI: 10.1007/s00170-017-0158-8.

Costa, R.J.S., Silva, F.J.G. and Campilho, R.D.S.G., 2017. A novel concept of agile assembly machine for sets applied in the automotive industry. The International Journal of Advanced Manufacturing Technology, [e-journal] 94, pp.3041-3063. DOI: 10.1007/s00170-017-0109-4.

Dahlgaard‐Park, SM. and Bendell, T., 2006. A review and comparison of six sigma and the lean organisations. The TQM magazine, [e-journal] 18(3), pp.255-262. DOI: 10.1108/09544780610659989.

Dave, Y. and Sohani, N., 2012. Single Minute Exchange of Dies: Literature Review. International Journal of Lean Thinking, [e-journal] 3(2), pp.27-37.

de Oliveira, J., Sá, J.C. and Fernandes, A., 2017. Continuous improvement through “Lean Tools” – An application in a mechanical company. Procedia Manufacturing, [e-journal] 13, pp.1082-1089. DOI: 10.1016/j.promfg.2017.09.139.

Dean Jr, J.W. and Bowen, D.E., 1994. Management theory and total quality: improving research and practice through theory development. The Academy of Management Review, [e-journal] 19(3), pp.392-418. DOI: 10.2307/258933.

Díaz-Reza, J., García-Alcaraz, J., Martínez-Loya, V., Blanco-Fernández, J., Jiménez-Macías, E. and Avelar-Sosa, L., 2016. The effect of SMED on benefits gained in maquiladora industry. Sustainability, [e-journal] 8(12), pp.1237. DOI: 10.3390/su8121237.

Dillon, A.P. and Shingo, S., 1985. A revolution in manufacturing: the SMED system. CRC Press.

Doiro, M., Fernández, F.J., Félix, M.J. and Santos, G., 2019. Machining operations for components in kitchen furniture: A comparison between two management systems. Procedia Manufacturing, [e-journal] 41, pp.10-17. DOI: 10.1016/j.promfg.2019.07.023.

Félix, M.J., Silva, S., Santos, G., Doiro, M. and Sá, J.C., 2019a. Integrated product and processes development in design: A case study. Procedia Manufacturing, [e-journal] 41, pp.296-303. DOI: 10.1016/j.promfg.2019.09.012.

Félix, M.J., Gonçalves, S., Jimenez, G. and Santos, G., 2019b. The contribution of design to the development of products and manufacturing processes in the Portuguese industry. Procedia Manufacturing, [e-journal] 41, pp.1055-1062. DOI: 10.1016/j.promfg.2019.10.033.

Ferreira, N., Santos, G. and Silva, R. 2019. Risk level reduction in construction sites: Towards a computer aided methodology – A case study. Applied Computing and Informatics, [e-journal] 15, pp.136-143. DOI: 10.1016/j.aci.2018.01.003.

Godina R., Pimentel, C., Silva, F.J.G. and Matias, J.C.O., 2018. A structural literature review of the Single Minute Exchange of Die: The latest trends. Procedia Manufacturing, [e-journal] 17, pp.783-790. DOI: 10.1016/j.promfg.2018.10.129.

Jasti, V.K.N. and Kodali, R., 2014. A literature review of empirical research methodology in lean manufacturing. International Journal of Operations & Production Management, [e-journal] 34(8), pp.1080-1122. DOI: 10.1108/IJOPM-04-2012-0169.

Jimenez, G., Santos, G., Sá, J.C., Ricardo, S., Pulido, J., Pizarro, A. and Hernández, H., 2019. Improvement of productivity and quality in the value chain through lean manufacturing - A case study. Procedia Manufacturing, [e-journal] 41, pp.882-889. DOI: 10.1016/j.promfg.2019.10.011.

Karim, A. and Arif-Uz-Zaman, K., 2013. A methodology for effective implementation of lean strategies and its performance evaluation in manufacturing organizations. Business Process Management Journal, [e-journal] 19(1), pp.169-196. DOI: 10.1108/14637151311294912.

Liker, J., 2004. The Toyota Way: Fourteen Management Principles From the World’s Greatest Manufacturer. New York: McGraw-Hill.

Machado, A.B., Silva, F.J.G., Sá, J.C., Barreiras, A., Ferreira, L.P., Pereira, M.T. and Santos, G., 2020. Improvement in External Logistics of an Automative Component Manufacturing Company Towards Costs Reduction. International Journal for Quality Research, [e-journal] 14(4), pp.1175-1190. DOI: 10.24874/IJQR14.04-12.

Martins, M., Godina R., Pimentel, C., Silva, F.J.G. and Matias, J.C.O., 2018. A practical study of the application of SMED to the Electrom-Beam machining in the automotive industry. Procedia Manufacturing, [e-journal] 17, pp.647-654. DOI: 10.1016/j.promfg.2018.10.113.

Moxham, C. and Greatbanks, R., 2001. Prerequisites for the implementation of the SMED methodology: A study in a textile processing environment. International Journal of Quality & Reliability Management, [e-journal] 18(4), pp.404-414. DOI: 10.1108/02656710110386798.

Murmura, F., Bravi, L. and Santos, G., 2021. Sustainable process and product innovation in the eyewear sector: The role of industry 4.0 enabling technologies. Sustainability, [e-journal] 13(1), pp.1-17. DOI: 10.3390/su13010365.

Neves, P., Silva, F.J.G., Ferreira, L.P., Gouveia, R. and Pimentel, C., 2018. Implementing Lean tools in the manufacturing process of trimming products. Procedia Manufacturing, [e-journal] 17, pp.696-704. DOI: 10.1016/j.promfg.2018.10.119.

Parwani, V. and Hu, G., 2021. Improving Manufacturing Supply Chain by Integrating SMED and Production Scheduling. Logistics, [e-journal] 5(4), pp.1-14. DOI: 10.3390/ logistics5010004.

Pereira, A.M.H. Silva, M.R., Domingues, M.A.G. and Sá, J.C., 2019. Lean Six Sigma Approach to Improve the Production Process in the Mould Industry: a Case Study. Quality Innovation Prosperity, [e-journal] 23(3), pp.103-121. DOI: 10.12776/qip.v23i3.1334.

Pinto, G.F.L., Silva, F.J.G., Campilho, R.D.S.G., Casais, R.B., Fernandes, A.J. and Baptista, A., 2019. Continuous improvement in maintenance: a case study in the automotive industry involving Lean tools. Procedia Manufacturing, [e-journal] 38, pp.1582-1591. DOI: 10.1016/j.promfg.2020.01.127.

Ribeiro, P., Sá, J.C., Ferreira, L.P., Silva, F.J.G., Pereira, M.T. and Santos, G., 2019. The Impact of the Application of Lean Tools for Improvement of Process in a Plastic Company: a case study. Procedia Manufacturing, [e-journal] 38, pp.765-775. DOI:10.1016/j.promfg.2020.01.104.

Risatti, H., 2013. A theory of craft: function and aesthetic expression. University of North Carolina Press.

Rodrigues, J., Sá, J.C.V., Ferreira, L. P., Silva, F. J.G. and Santos, G., 2019. Lean Management “Quick-Wins”: Results of Implementation. A Case Study. Quality Innovation Prosperity, [e-journal] 23(3), pp.3-21. DOI: 10.12776/qip.v23i3.1291.

Rosa, C., Silva, F.J.G. and Ferreira, L.P., 2017. Improving the quality and productivity of steel wire-rope assembly lines for the automotive industry. Procedia Manufacturing, [e-journal] 11, pp.1035-1042. DOI: 10.1016/j.promfg.2017.07.214.

Rosa, C., Silva, F.J.G., Ferreira, L.P. and Campilho, R., 2017. SMED methodology: the reduction of setup times for steel wire-rope assembly lines in the automotive industry, Procedia Manufacturing, [e-journal] 13, pp.1034-1042. DOI: 10.1016/j.promfg.2017.09.110.

Rosa C., Silva, F.J.G., Ferreira, L.P., Pereira, T. and Gouveia, R., 2018. Establishing standard methodologies to improve the production rate of assembly lines used for low-added value products. Procedia Manufacturing, [e-journal] 17, pp.555-562. DOI: 10.1016/j.promfg.2018.10.096.

Rüttimann, B.G., 2017. Lean compendium: introduction to modern manufacturing theory. Springer.

Sá, J.C., Amaral, A., Barreto, L., Carvalho, F. and Santos, G., 2019. Perception of the importance to implement ISO 9001 in organizations related to people linked to quality-an empirical study. International Journal for Quality Research, [e-journal] 13(4), pp.1055-1070. DOI: 10.24874/IJQR13.04-20.

Sá, J.C., Vaz, S., Carvalho, O., Morgado, L., Lima V., Fonseca, L., Doiro, M. and Santos, G., 2020. A model of integration ISO 9001 with Lean six sigma and main benefits achieved. Total Quality Management & Business Excellence, in press. DOI: 10.1080/14783363.2020.1829969.

Santos, G., Mandado, E., Silva, R. and Doiro, M., 2019a. Engineering learning objectives and computer assisted tools. European Journal of Engineering Education, [e-journal] 44(4), pp.616-628. DOI: 10.1080/03043797.2018.1563585.

Santos, G., Murmura, F. and Bravi, L., 2019. Developing a model of vendor rating to manage quality in the supply chain. International Journal of Quality and Service Sciences, [e-journal] 11(1), pp.34-52. DOI: 10.1108/IJQSS-06-2017-0058.

Santos, G., Sá, J.C., de Oliveira, J., Ramos, D.G. and Ferreira, C., 2019b. Quality and safety continuous improvement through lean tools. In: F.J.G. Silva and L.C.P. Ferreira, ed. 2019. Lean Manufacturing: Implementation, Opportunities and Challenges. New York: Nova Science Publishers. pp.165-188.

Santos, G., Gomes, S., Braga, V., Braga, A., Lima, V., Teixeira, P. and Sá, J.C., 2019c. Value creation through quality and innovation – a case study on Portugal. TQM Journal, [e-journal] 31(6), pp.928-947. DOI: 10.1108/TQM-12-2018-0223.

Silva, F.J.G. and Gouveia, R.M., 2020. Sustainable Production Cases. Cleaner Production – Toward a Better Future. Switzerland: Springer Nature. DOI: 10.1007/978-3-030-23165-1_8.

Sousa, E., Silva, F.J.G., Ferreira, L.P., Pereira, M.T., Gouveia, R. and Silva, R.P., 2018. Applying SMED methodology in cork stoppers production. Procedia Manufacturing, [e-journal] 17, pp.611-622. DOI: 10.1016/j.promfg.2018.10.103.

Sundar, R., Balaji, A.N. and Kumar, R.M.S., 2014. A review on lean manufacturing implementation techniques. Procedia Engineering, [e-journal] 97, pp.1875-1885. DOI: 10.1016/j.proeng.2014.12.341.

Talapatra, S., Santos, G., Uddin, K. and Carvalho, F., 2019. Main benefits of integrated management systems through literature Review. International Journal for Quality Research, [e-journal] 13(4), pp.1037-1054. DOI: 10.24874/IJQR13.04-19.

Tomac, N., Radonja, R. and Bonato, J., 2019. Analysis of Henry Ford’s contribution to production and management. Scientific Journal of Maritime Research, [e-journal] 33, pp.33-45. DOI: 10.31217/p.33.1.4.

Van Goubergen, D. and Van Landeghem, H., 2002. Rules for integrating fast changeover capabilities into new equipment design. Robotics and computer-integrated manufacturing, [e-journal] 18(3-4), pp.205-214. DOI: 10.1016/s0736-5845(02)00011-x.

Vieira, T., Sá, J.C., Lopes, M.P., Santos, G., Félix, M.J., Ferreira, L.P., Silva, F.J.G. and Pereira, M.T., 2019. Optimization of the cold profiling process through SMED. Procedia Manufacturing, [e-journal] 38, pp.892-899. DOI: 10.1016/j.promfg.2020.01.171.

Womack, J.P. and Jones, D.T., 2003. Lean Thinking: Banish Waste and Create Wealth in Your Corporation. 2nd ed. London: Free Press.

Zgodavova, K., Hudec, O. and Palfy, P., 2017. Culture of quality: insight into foreign organisations in Slovakia. Total Quality Management & Business Excellence, [e-journal] 28(9-10), pp.1054-1075. DOI: 10.1080/14783363.2017.1309120.


José C. Sá
Gilberto Santos
gsantos@ipca.pt (Primary Contact)
Francisco J.G. Silva
Luís P. Ferreira
Maria T. Pereira
Silva, A., Sá, J. C., Santos, G., Silva, F. J. ., Ferreira, L. P. ., & Pereira, M. T. . (2021). A Comparison of the Application of the SMED Methodology in Two Different Cutting Lines. Quality Innovation Prosperity, 25(1), 124–149. https://doi.org/10.12776/qip.v25i1.1446

Article Details

TRIZ and Lean Philosophies Applied Together in Management Activities

Teresa L.M. Morgado, Jorge Sandiães, Helena V.G. Navas
Abstract View : 852
Download :381