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This study focuses on implementing the SMED (Single Minute Exchange of Die) methodology in a production cell for Exhaust Gas Recirculation (EGR) valves within the automotive industry. The research aimed to reduce setup times, improve Overall Equipment Effectiveness (OEE), and standardise changeover processes while mitigating safety risks. The Action Research methodology guided the study, beginning with problem identification and detailed analysis through setup observation and data collection. Improvements were developed and structured into an action plan using the 5W1H framework, complemented by Lean tools such as 5S and Visual Management. Results were iteratively analysed and improved. The implementation yielded significant improvements: a 28% reduction in setup time when switching from the valve of Client A to Client B, and 44% from the valve of Client B to Client A. Operator travel distances during changeovers decreased by 58.5%, translating into annual savings of approximately €2,000 based on 2023 data. Given the company’s strategy to increase reference changes to lower finished goods inventory, cost savings are expected to scale accordingly. Furthermore, OEE improved from an average of 79% (January–June 2023) to 86% (same period in 2024), reinforcing the value of SMED in optimizing production efficiency and supporting business objectives.

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Implementation of SMED Methodology in an EGR Valve Production Cell for the Automotive Industry

  • 会议论文

  • 发表日期：

    2025年

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  • Andreia Pereira,
  • Ângela Silva

摘要

This study focuses on implementing the SMED (Single Minute Exchange of Die) methodology in a production cell for Exhaust Gas Recirculation (EGR) valves within the automotive industry. The research aimed to reduce setup times, improve Overall Equipment Effectiveness (OEE), and standardise changeover processes while mitigating safety risks. The Action Research methodology guided the study, beginning with problem identification and detailed analysis through setup observation and data collection. Improvements were developed and structured into an action plan using the 5W1H framework, complemented by Lean tools such as 5S and Visual Management. Results were iteratively analysed and improved. The implementation yielded significant improvements: a 28% reduction in setup time when switching from the valve of Client A to Client B, and 44% from the valve of Client B to Client A. Operator travel distances during changeovers decreased by 58.5%, translating into annual savings of approximately €2,000 based on 2023 data. Given the company’s strategy to increase reference changes to lower finished goods inventory, cost savings are expected to scale accordingly. Furthermore, OEE improved from an average of 79% (January–June 2023) to 86% (same period in 2024), reinforcing the value of SMED in optimizing production efficiency and supporting business objectives.