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SMED Simulation in Optimising the Operating Output of Tandem Press Line in the Automotive Industry using WITNESS Software

The automotive industry is one of the most advanced industries in the world. The demand for vehicles keeps increasing over time, mainly influenced by technology’s sophistication and impressive designs. This research is focusing on the production performance of the stamping process in Malaysia’s auto...

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Main Authors: Azizul Qayyum, Basri, N. M. Zuki, N. M., Nelfiyanti, Nelfiyanti, Yusrizal, Yusoof
Format: Article
Language:English
Published: Universiti Malaysia Pahang 2021
Subjects:
TS Manufactures
Online Access:http://umpir.ump.edu.my/id/eprint/32091/1/SMED%20Simulation%20in%20Optimising.pdf
http://umpir.ump.edu.my/id/eprint/32091/
https://doi.org/10.15282/ijame.18.3.2021.05.0682
https://doi.org/10.15282/ijame.18.3.2021.05.0682
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spelling my.ump.umpir.320912021-09-20T01:55:37Z http://umpir.ump.edu.my/id/eprint/32091/ SMED Simulation in Optimising the Operating Output of Tandem Press Line in the Automotive Industry using WITNESS Software Azizul Qayyum, Basri N. M. Zuki, N. M. Nelfiyanti, Nelfiyanti Yusrizal, Yusoof TS Manufactures The automotive industry is one of the most advanced industries in the world. The demand for vehicles keeps increasing over time, mainly influenced by technology’s sophistication and impressive designs. This research is focusing on the production performance of the stamping process in Malaysia’s automotive industry. The main issue observed and evidenced in data collected from industry players is that an unacceptably long time is taken in the die/tooling change process, which grossly affects the planned production output. The most significant direct impact on this situation is the increase in operating costs due to additional time taken to meet the planned production output. Therefore, this research aims to establish a new framework that can optimise the efficiency of the dies changeover process, which could lower the overall production cost, which could partially transfer the saving to the consumers. The study was conducted in two stages; the first is on data collection correlates with the automotive stamping premise to create a simulation procedure, and the second is to analyse the current production output using WITNESS simulation. These simulated output data have later been compared to the actual industrial data. Using a systematic dies changeover process, a new alternative framework was proposed. The framework combined single minute exchange of die (SMED), lean tools and simulation to become an integrated single minute exchange of die (ISMED). It shows that the proposed method decreased the changeovers processes from the initial of 1509.5 seconds to 750.75 seconds, then further reduced to 569.75 seconds, with the nett time reduction of 62.2%. The result shows that the daily production output has increased gradually from 1100 pieces to 1500 pieces, further increasing to 2145 pieces. As evidenced in analytical data, it is believed that this new framework can strengthen the total output in the manufacturing process, especially in the manufacturing of automotive stamping parts. Universiti Malaysia Pahang 2021 Article PeerReviewed pdf en cc_by_4 http://umpir.ump.edu.my/id/eprint/32091/1/SMED%20Simulation%20in%20Optimising.pdf Azizul Qayyum, Basri and N. M. Zuki, N. M. and Nelfiyanti, Nelfiyanti and Yusrizal, Yusoof (2021) SMED Simulation in Optimising the Operating Output of Tandem Press Line in the Automotive Industry using WITNESS Software. International Journal of Automotive and Mechanical Engineering (IJAME), 18 (3). pp. 8895-8906. ISSN 1985-9325(Print); 2180-1606 (Online) https://doi.org/10.15282/ijame.18.3.2021.05.0682 https://doi.org/10.15282/ijame.18.3.2021.05.0682
institution Universiti Malaysia Pahang
building UMP Library
collection Institutional Repository
continent Asia
country Malaysia
content_provider Universiti Malaysia Pahang
content_source UMP Institutional Repository
url_provider http://umpir.ump.edu.my/
language English
topic TS Manufactures
spellingShingle TS Manufactures
Azizul Qayyum, Basri
N. M. Zuki, N. M.
Nelfiyanti, Nelfiyanti
Yusrizal, Yusoof
SMED Simulation in Optimising the Operating Output of Tandem Press Line in the Automotive Industry using WITNESS Software
description The automotive industry is one of the most advanced industries in the world. The demand for vehicles keeps increasing over time, mainly influenced by technology’s sophistication and impressive designs. This research is focusing on the production performance of the stamping process in Malaysia’s automotive industry. The main issue observed and evidenced in data collected from industry players is that an unacceptably long time is taken in the die/tooling change process, which grossly affects the planned production output. The most significant direct impact on this situation is the increase in operating costs due to additional time taken to meet the planned production output. Therefore, this research aims to establish a new framework that can optimise the efficiency of the dies changeover process, which could lower the overall production cost, which could partially transfer the saving to the consumers. The study was conducted in two stages; the first is on data collection correlates with the automotive stamping premise to create a simulation procedure, and the second is to analyse the current production output using WITNESS simulation. These simulated output data have later been compared to the actual industrial data. Using a systematic dies changeover process, a new alternative framework was proposed. The framework combined single minute exchange of die (SMED), lean tools and simulation to become an integrated single minute exchange of die (ISMED). It shows that the proposed method decreased the changeovers processes from the initial of 1509.5 seconds to 750.75 seconds, then further reduced to 569.75 seconds, with the nett time reduction of 62.2%. The result shows that the daily production output has increased gradually from 1100 pieces to 1500 pieces, further increasing to 2145 pieces. As evidenced in analytical data, it is believed that this new framework can strengthen the total output in the manufacturing process, especially in the manufacturing of automotive stamping parts.
format Article
author Azizul Qayyum, Basri
N. M. Zuki, N. M.
Nelfiyanti, Nelfiyanti
Yusrizal, Yusoof
author_facet Azizul Qayyum, Basri
N. M. Zuki, N. M.
Nelfiyanti, Nelfiyanti
Yusrizal, Yusoof
author_sort Azizul Qayyum, Basri
title SMED Simulation in Optimising the Operating Output of Tandem Press Line in the Automotive Industry using WITNESS Software
title_short SMED Simulation in Optimising the Operating Output of Tandem Press Line in the Automotive Industry using WITNESS Software
title_full SMED Simulation in Optimising the Operating Output of Tandem Press Line in the Automotive Industry using WITNESS Software
title_fullStr SMED Simulation in Optimising the Operating Output of Tandem Press Line in the Automotive Industry using WITNESS Software
title_full_unstemmed SMED Simulation in Optimising the Operating Output of Tandem Press Line in the Automotive Industry using WITNESS Software
title_sort smed simulation in optimising the operating output of tandem press line in the automotive industry using witness software
publisher Universiti Malaysia Pahang
publishDate 2021
url http://umpir.ump.edu.my/id/eprint/32091/1/SMED%20Simulation%20in%20Optimising.pdf
http://umpir.ump.edu.my/id/eprint/32091/
https://doi.org/10.15282/ijame.18.3.2021.05.0682
https://doi.org/10.15282/ijame.18.3.2021.05.0682
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score 13.211869

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