www.stabilo.com

SMED Presentations - Improvement for Marker 3

www.stabilo.com

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

www.stabilo.com

Before SMED implementationSee videos:

www.stabilo.com

(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

www.stabilo.com

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

www.stabilo.com

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

www.stabilo.com

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

www.stabilo.com

After SMED implementationsSee videos:

www.stabilo.com

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

www.stabilo.com

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

www.stabilo.com

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

www.stabilo.com

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