Analysis and Improvement of Setup Times at a Metalworking Company

Nowadays, companies are confronted by numerous challenges due to market developments, globalization, as well as the emerging 4th industrial revolution. Faced with this competitive pressure, many companies have sought to adopt measures for continuous improvement supported by Lean Production philosophy. This study aims at evaluating the impact of the implementation of Lean tools such as Standard Work and SMED (Single Minute Exchange of Dies) in a working cell of a metalworking company located in Portugal. In addition, the study attempted to address these challenges by creating a tool cart for setups to reduce setup times, increase work cell availability and, as a result, improve operational performance of the company. By implementing these Lean tools, the work cell capacity was improved, while setup times were significantly reduced. This study is based on action-research methodology, which provides a systematic and efficient framework for solving real enterprises problems and making any needed refinements.