SUNConferences, Southern African Institute for Industrial Engineering 2014

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IMPROVING FORGE CHANGEOVER PERFORMANCE AT AN AUTOMOTIVE COMPONENT SUPPLIER
Jarred Durbach, Dieter Hartmann, Teresa Hattingh

Last modified: 2014-06-26

Abstract


A manufacturer of aluminium  parts  for the automotive industry is currently constrained by its  forging process.   Tool changes are required on the forge to produce different  part  types. This paper describes a project that was undertaken to reduce  changeover time  and improve the quality of tool changeovers. A study of current practices revealed high variability in the changeover times and showed that changeover performance could be  improved by reducing the effort required to perform changeover tasks, reducing the  need for  making  setting adjustments, removing opportunities for making errors and standardising the procedure.   The design solution includes  changes  to tools and equipment,  improvements to tool handling and fastening methods and the use of a changeover trolley. A new, standardised process is provided,  focusing on task quality and  not time. Changes to the organisation’s strategy,  culture  and performance measures  are also required for improvements to be sustainable. The resulting improvements will allow more tool changes to be performed, reducing batch sizes and the amount of work in progress required in the plant, ultimately enabling the company to plan production closer to customer demand.

 


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