What is it about?

The aim of this paper is to un cover the significance of Quick Changeovers in Die-casting foundry environments. It gives set-up instructions and guidelines to prepare the Standardized Set-up Procedure without ignoring actual constraints in foundries. The paper dwells with a case study in medium scale piston foundry to generate an Integrated Set-up Reduction Approach, which is utilizing respective Industrial Engineering tools under the flag of SMED, for faster Set-ups. Then at last it did the Empirical Analysis of the financial / non-financial benefits incurred from set-up reductions.

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Why is it important?

The paper’s approach is to describe the feasibility of quick changeovers in foundry SMEs with the strategic and coherent implementation of the revolutionary Japanese Technique called “SMED”.


Set-up activities are vital part of production lead-time of any product and so affect overall product cost. Tools like Pareto analysis, Root-cause analysis and Method study have been used to analyze the existing procedure of set-ups. SMED can eliminate the unwanted activities, externalize the internal activities, if possible and reduce them by simplification or standardization. Implementation of some other tools like 5S, Poke-Yoke and specific Tool-Kits are suggested to further reduce the set-ups positively.

Dr Bikram Jit Singh
MMDU Mullana

Read the Original

This page is a summary of: SMED: for quick changeovers in foundry SMEs, International Journal of Productivity and Performance Management, December 2009, Emerald, DOI: 10.1108/17410401011006130.
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