ABSTRACT
Lean manufacturing philosophy is continually strive to eliminate the nun-value added
activities, minimize the delivery cycle time and improve the quality of products. Most
manufacturing companies adopt lean in order to meet customer expectations and
become more competitive in the market. Implementation of Lean enterprise is an
efficient and effective way to reduce the cost of the enterprise without incurring high
capital expenditures. SMED is a popular lean tool used for dramatically reducing the
set-up time for the machine, which is a set of techniques enabling for the
replacement of tooling or set a production line in less time than 10 minutes. This
paper focuses on implementing SMED methodology in a mass production company
for food industries in order to reduce changeover time. The objectives of this paper
are decreasing the setup times of the production line to enable the production
flexibility and increase the maneuverability between different products according to
customer needs. This paper monitoring carefully all production processes to identify
all wasted time between processes and find ways to eliminate or decrease it. The
achieved results indicate that implementation of SMED in the company has a
significant impact on decreasing the setup times and increasing the total productivity
and the net profit. The changeover time reduced by 25%, and the OEE increased
from 48% to 70%, also, the sales opportunities increased by 465,600 EGP per year.