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SMED Presentations - Improvement for Marker 3
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Target : Marker 3 Machine(1)For this SMED implementations, we focus on the Marker 3
machines (2)Below are the some background info on the Marker 3 machine:
Machine: Marker 3 MachinesProducts : Marker Pen (Bullet Permanent & Bullet
Whiteboard)
Operators needed for operator: Two (Leader & Operator)(3) The changeover that are focused in this SMED studies are changeover colours from colour 46 to colour 56
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Before SMED implementationSee videos:
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(1)After recording the videos, all the movement and actions are recorded down in the spaghetti maps and SMED form
(2) All the activities are analysed into internal and external setup(3)The external setup are identified and pulled out from changeover
time (4)Meanwhile the internal setup are rearranged with smooth
workflow
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Improvements to reduce changeover time
(1)Observation 1: Operator need to go for a long distance to get the gloves and rags
Improvement 1 : Relocate the items for internal setup at or near the m/cE.G : Relocate the rags and glove at the m/c
(2) Observation 2: Operator waiting due to waiting for raw material to start changeover Improvement 2: Restructure workflow (E.G see next slides) so that operator can start changeover while pending for raw materials. Retrain operators.
Rag and glove box are located at near ink nozzle
(After Improvement)
Operator need to walk for
glove and rags
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Leader Operator
1. Get new ink drums from store2. Scan new ink drum transfer from
store to m/c3. Transfer ink drum to the m/c
1. Uninstall ink nozzles2. Wash nozzles (auto) using IPA3. Empty bowl feeder of plastic
parts while washing nozzles
4. Stop washing nozzles and install nozzle back to the m/c5. Tally the new ink with job card6. Pump new ink to the nozzles7. Remove output (previous running articles) from the machine into output carton & paste output label
New Ink drums4. Take the plastic parts from the moulding area5. Scan/record new plastic part transfer from moulding to m/c 6. Transfer new plastic parts to m/c
New plastic parts
8. Tally new plastic parts with job card9. Pour the plastic parts into bowl feeder10. Write m/c records & output records 11. Start production
7. Take old ink drum from m/c8. Scan old ink drum transfer from m/c to store9. Transfer ink drum to the m/c 10. Test run & adjust m/c settings11. Start production
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Observation 3: Leader need to search for trolley each time need to transfer the raw materialsImprovement 3: Foldable trolley (meant for marker m/c) are placed near the machine . After using, the foldable trolley can be folded to avoid less clutters
Trolley for plastic parts
Trolley for ink drums
Foldable trolley for both ink drums and
plastic parts
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After SMED implementationsSee videos:
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Further suggested improvements(1)Replacing the screws at nozzles to ratchet type screws for easier
installing and uninstalling nozzles Purpose is to reduce the time operator spends on retrieving the Allen key as well as the time taken to unscrew the nozzles. The ratchet screws can unscrew the nozzles with one turn or less and less time consuming
Screws that hold the nozzles
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Further suggested improvements(2) Modify the bowl feeder so that the bowl feeder doesn’t need to be emptied using manual methods which are time consuming
Referring to the diagrams on right, there is trapdoor (at base) that can be open during changeover to auto emptying the bowl feeder
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Further suggested improvements(3) Additional industrial weighing scales to be put at the ink storage room so that there won’t be any traveling needed to Impi storage room
Before Improvement
After Improvement
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Further suggested improvements(4) Adjustment to the AC pusher / ink nozzles can be quantified using micro meter screws instead of using Allen key method where the minute adjustment can be done