Open Access
Figari Massa, Roberto
Graduate Program:
Industrial Engineering
Master of Science
Document Type:
Master Thesis
Date of Defense:
Committee Members:
  • Richard Allen Wysk, Thesis Advisor
  • Arunachalam Ravindran, Thesis Advisor
  • Changeover
  • Setup
  • Startup
  • SMED
  • LEAN
Enterprise management systems still use Economic Order Quantity (EOQ) systems to determine the batch size of production lots. Using this methodology exacerbates the impact of setup time on the supply chain. High volume production activities enable the production of high value products to customers but they also bring a variety of challenges to the shop floor. High volume efficiency comes with a variety of inflexibility problems. Changing from one product to another can be highly problematic and expensive in terms of waste and unproductive time; therefore, the economic order quantity turns out to be very large causing poor responsiveness and requiring high inventory levels. This has been recognized for more than two decades and the practice of setup reduction has taken on a number of systematic approaches, the most notable called SMED (or Single Minute Exchange of Dies). The focus of SMED is to reduce from hours to minutes the time required to move from producing one product to another. This research develops a methodology to analyze and redesign the setup process, at a high volume production system of the Latin American production facilities, of a global leading multinational company in the health and hygiene industry. A detailed description of the setup process is provided as the process is currently conducted. The time and resources required for the setup are also documented so that better setup solutions can be derived. Finally, a redesign of the setup process is provided and validated. The new design reduces the mechanical time for setup from 3 hours to 1 hour