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Ställtidsreducering på Mälarplast AB
Mälardalen University, School of Innovation, Design and Engineering.
2016 (Swedish)Independent thesis Basic level (university diploma), 10 credits / 15 HE creditsStudent thesis
Abstract [en]

The problem

Modern manufacturing needs to be flexible. Flexibility is achieved by smaller lot sizes of the parts manufactured, which places higher demands on keeping the setup times low. Setup time is the time it takes to switch the production from manufacturing product A to the first approved product B. The setup time can be divided into internal setup time (the time when the machine is stationary), and external setup time (when the machine is active). In many productions the tool exchange is a large part of the total manufacturing time. Based on this, the aim of this thesis can be summarized into two questions:  

  1. What factors affect the setup time?
  2. How can the setup time be reduced?

Case study

The case study was performed at Mälarplast AB, where a distinction is made to reduction of setup time of the company’s injection molding. The case study consisted of observations, interviews and time-studies.

The theoretical framework for this study consisted of a literature study conducted on how to reduce setup-time.

A common method for reduction of setup time is SMED, which stands for single minute exchange of dies. This method, which was used in this study involves separating the production of internal and external setup. The seven wastes were also studied, and formed the basis for the suggested improvements that have been developed.

During the study it was noticed that the employees moved around a lot during setups. They had to retrieve missing tools and components, which lead to several rounds of walking. Shortcomings in the working routines were also noticed. Therefore, solutions to minimize the employees’ movement were developed. 


In the beginning of the study a time study was done for the machine T6. The time for the work procedures that were included inthe setup time was 80.5 minutes. By moving internal setup time to external setup time, using parallel operations and refining other processes the setup time could be reduce by approximate 50 % without any expensive investments.

Place, publisher, year, edition, pages
Keyword [sv]
SMED, Ställtidsreducering, 5S, slöserier, TPS
National Category
Engineering and Technology
URN: urn:nbn:se:mdh:diva-32228OAI: diva2:943374
Subject / course
Product and Process Development
Available from: 2016-06-28 Created: 2016-06-27 Last updated: 2016-06-28Bibliographically approved

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