The impact of single minute exchange of die and total productive maintenance on overall equipment effectiveness

Ondra, Pavel

dc.title	The impact of single minute exchange of die and total productive maintenance on overall equipment effectiveness	en
dc.contributor.author	Ondra, Pavel
dc.relation.ispartof	Journal of Competitiveness
dc.identifier.issn	1804-171X Scopus Sources, Sherpa/RoMEO, JCR
dc.identifier.issn	1804-1728 Scopus Sources, Sherpa/RoMEO, JCR
dc.date.issued	2022
utb.relation.volume	14
utb.relation.issue	2
dc.citation.spage	113
dc.citation.epage	132
dc.type	article
dc.language.iso	en
dc.publisher	Tomas Bata University in Zlín
dc.identifier.doi	10.7441/joc.2022.03.07
dc.relation.uri	https://www.cjournal.cz/index.php?hid=clanek&bid=archiv&cid=457&cp=
dc.relation.uri	https://www.cjournal.cz/files/457.pdf
dc.subject	single minute exchange of die	en
dc.subject	total productive maintenance	en
dc.subject	overall equipment effectiveness	en
dc.subject	competitiveness	en
dc.subject	lean company	en
dc.subject	industrial companies	en
dc.subject	Czech Republic	en
dc.description.abstract	Due to intense global competition, manufacturing companies need to improve and optimize productivity, increase production and flexibility, and gain competitive advantages. Companies have begun to look for new approaches and strategies in the field of production management. This includes tools like Single Minute Exchange of Die (SMED) and Total Productive Maintenance (TPM), which aim to manage machines and equipment, reduce waste and lead time, and ensure and enhance competitiveness. The main objective of this study is to explore the connection and the context of the use of industrial engineering tools, namely SMED and TPM, and to monitor and evaluate Overall Equipment Effectiveness (OEE) in industrial companies in the Czech Republic. A comprehensive questionnaire survey of 200 companies and a detailed evaluation of the operational performance of 92 companies were carried out from the third quarter of 2019 to the third quarter of 2020. It was found out that 20.5% of companies implemented SMED, 26.5% of companies implemented TPM, and 54.0% of companies did not monitor and evaluate OEE. The research confirms the theoretical link between SMED and OEE and between OEE and TPM. The statistical significance of the use of SMED and TPM separately was not demonstrated. However, the mutual interaction of using TPM and SMED on the OEE level was proved.	en
utb.faculty	Faculty of Management and Economics
dc.identifier.uri	http://hdl.handle.net/10563/1011193
utb.identifier.obdid	43883674
utb.identifier.scopus	2-s2.0-85140052248
utb.identifier.wok	000883309700008
utb.source	j-scopus
dc.date.accessioned	2022-11-29T07:49:18Z
dc.date.available	2022-11-29T07:49:18Z
dc.description.sponsorship	Tomas Bata University in Zlin, TBU
dc.description.sponsorship	Internal Grant Agency of FaME TBU in Zlin; TBU in Zlin [IGA/FaME/2019/007]
dc.rights	Attribution 4.0 International
dc.rights.uri	https://creativecommons.org/licenses/by/4.0/
dc.rights.access	openAccess
utb.ou	Department of Industrial Engineering and Information Systems
utb.contributor.internalauthor	Ondra, Pavel
utb.fulltext.affiliation	Pavel Ondra Contact information Ing. Pavel Ondra Tomas Bata University in Zlín Faculty of Management and Economics Department of Industrial Engineering and Information Systems Czech Republic E-mail: ondra@utb.cz ORCID: 0000-0002-0145-9134
utb.fulltext.dates	Received: September, 2021 1st Revision: August, 2022 Accepted: September, 2022
utb.fulltext.references	1. Ahmad, N., Hossen, J., & Ali, S. M. (2018). Improvement of Overall Equipment Efficiency of Ring Frame through Total Productive Maintenance: A Textile Case. The International Journal of Advanced Manufacturing Technolog y, 94 (1-4), 239–256. https://doi.org/10.1007/s00170-017-0783-2 2. Ahuja, I. P. S., & Khamba, J. S. (2008a). Assessment of Contributions of Successful TPM Initiatives towards Competitive Manufacturing. Journal of Quality in Maintenance Engineering, 14 (4), 356–374. https://doi.org/10.1108/13552510810909966 3. Antosz, K., & Pacana, A. (2018). Comparative Analysis of the Implementation of the SMED Method on Selected Production Stands. Technical Gazette, 25 (2), 276–282. https://doi.org/10.17559/TV-20160411095705 4. Bashar, A., Hasin, A. A., & Jahangir, N. (2022). Linkage between TPM, People Management and Organizational Performance. Journal of Quality in Maintenance Engineering, 28 (2), 350–366. https://doi.org/10.1108/JQME-11-2019-0105 5. Brah, S. A., & Chong, W. K. (2004). Relationship between Total Productive Maintenance and Performance. International Journal of Production Research, 42 (12), 2383–2401. https://doi.org/10.1080/00207540410001661418 6. Branska, L., Pecinova, Z., Patak, M., Stankova, M., & Kholova, P. (2016). Maintenance Management Systems in the Czech Enterprises of Chemical and Food Industries. Trendy Ekonomiky a Managementu, 10 (27), 20–29. https://doi.org/10.13164/trends.2016.27.20 7. Chaurey, S., Kalpande, S. D., Gupta, R. C., & Toke, L. K. (2021). A Review on the Identification of Total Productive Maintenance Critical Success Factors for Effective Implementation in the Manufacturing Sector. Journal of Quality in Maintenance Engineering, ahead-of-print. https://doi.org/10.1108/JQME-11-2020-0118 8. Chikwendu, O. C., Chima, A. S., & Edith, M. C. (2020). The Optimization of Overall Equipment Effectiveness Factors in a Pharmaceutical Company. Heliyon, 6 (4), e03796. https://doi.org/10.1016/j.heliyon.2020.e03796 9. Cushman & Wakefield. (2021). Czechia Remains the Best Manufacturing Destination in Europe. Retrieved from https://cushwk.co/3QB9sYP 10. D’Orazio, L., Messina, R., & Schiraldi, M. M. (2020). Industry 4.0 and World Class Manufacturing Integration: 100 Technologies for a WCM-I4.0 Matrix. Applied Sciences, 10 (14), 4942. https://doi.org/10.3390/app10144942 11. De Andrade, C. T. A., De Gusmão, A. P. H., & Silva, W. (2021). World Class Manufacturing Performance Measurement Using a Maturity Model and the FlowSort Method. International Journal of Production Research, 59 (24), 7374–7389. https://doi.org/10.1080/00207543.2021.1970845 12. De Felice, F., Laura, P., Luigi, R., & Antonella, P. (2019). Previous Studies and Differences Between Lean Manufacturing and World Class Manufacturing. International Journal of Information Technolog y & Decision Making, 18 (6), 1941–1966. https://doi.org/10.1142/S0219622019500391 13. De La Vega, M., Baez-Lopez, Y., Limon-Romero, J., Tlapa, D., Flores, D. L., Bordón, M. I. R., & Maldonado-Macias, A. A. (2020). Lean Manufacturing Critical Success Factors for the Transportation Equipment Manufacturing Industry in Mexico. IEEE Access, 8, 168534– 168545. https://doi.org/10.1109/ACCESS.2020.3023633 14. Eurostat. (2019). Output of Economic Activities in the EU Member States. Retrieved from https://bit.ly/3A6okaB 15. Filla, J. (2016). The Single Minute Exchange of Die Methodology in a High-Mix Processing Line. Journal of Competitiveness, 8 (2), 59–69. https://doi.org/10.7441/joc.2016.02.05 16. Gálová, K., Rajnoha, R., & Ondra, P. (2018). The Use of Industrial Lean Management Methods in the Economics Practice: An Empirical Study of the Production Companies in the Czech Republic. Polish Journal of Management Studies, 17 (1), 93–104. https://doi.org/10.17512/pjms.2018.17.1.08 17. Gherghea, I. C., Bungau, C., Indre, C. I., & Negrau, D. C. (2021). Enhancing Productivity of CNC Machines by Total Productive Maintenance (TPM) Implementation. IOP Conference Series: Materials Science and Engineering, 1169, 012035. https://doi.org/10.1088/1757-899X/1169/1/012035 18. Godina, R., Rodrigues, E. M. G., & Matias, J. C. O. (2018). An Alternative Test of Normality for Improving SPC in a Portuguese Automotive SME. In E. Viles, M. Ormazábal, & A. Lleó (Eds.), Closing the Gap between Practice and Research in Industrial Engineering. Springer. https://doi.org/10.1007/978-3-319-58409-6_31 19. Harrell, F. E. (2015). Regression Modeling Strategies. New York: Springer. 20. Jasial, S. S., Pal, S. S., & Thakur, V. (2014). Improving the Overall Equipment Effectiveness of a Machine: Case of a Float Glass Manufacturer in India. IUP Journal of Operations Management, 13 (3), 56–64. Retrieved from http://bit.ly/33Dx1Il 21. Kalpande, S. D., & Toke, L. K. (2022). Reliability Analysis and Hypothesis Testing of Critical Success Factors of Total Productive Maintenance. International Journal of Quality & Reliability Management, ahead-of-print. https://doi.org/10.1108/IJQRM-03-2021-0068 22. Kechaou, F., Addouche, S. A., & Zolghadri, M. (2022). A Comparative Study of Overall Equipment Effectiveness Measurement Systems. Production Planning & Control, ahead-of-print. https://doi.org/10.1080/09537287.2022.2037166 23. Khafizov, I. I., & Nurullin, I. G. (2017). Product Quality as the Main Factor of Increase of Competitiveness. IOP Conference Series: Materials Science and Engineering, 240, 012039. https://doi.org/10.1088/1757-899X/240/1/012039 24. Krachangchan, K., & Thawesaengskulthai, N. (2018). Loss Time Reduction for Improve Overall Equipment Effectiveness (OEE). The 5th International Conference on Industrial Engineering and Applications (ICIEA), Singapore. IEEE. https://doi.org/10.1109/IEA.2018.8387132 25. Liu, X., & Koirala, H. (2012). Ordinal Regression Analysis: Using Generalized Ordinal Logistic Regression Models to Estimate Educational Data. Journal of Modern Applied Statistical Methods, 11 (1), 242–254. https://doi.org/10.22237/jmasm/1335846000 26. Logesh, B., Kuppuraj, R., & Augustine, A. (2017). Experimental Investigation to Deploy Overall Equipment Effectiveness (OEE) in CNC Machining Line of an Automobile Component Production Industry Using TPM. International Journal of Scientific Research in Science, Engineering and Technolog y, 3 (8), 99–105. https://doi.org/10.32628/IJSRSET1173838 27. Malindzakova, M., Malindzak, D., & Garaj, P. (2021). Implementation of the Single Minute Exchange of Dies Method for Reducing Changeover Time in a Hygiene Production Company. International Journal of Industrial Engineering and Management, 12 (4), 243–252. http://doi.org/10.24867/IJIEM-2021-4-291 28. Manjunatha, B., Srinivas, T. R., & Ramachandra, C. G. (2018). Implementation of Total Productive Maintenance (TPM) to Increase Overall Equipment Efficiency of a Hotel Industry. MATEC Web of Conferences, 144, 05004. https://doi.org/10.1051/matecconf/201814405004 29. Mwanza, B. G., & Mbohwa, C. (2015). Design of a Total Productive Maintenance Model for Effective Implementation: Case Study of a Chemical Manufacturing Company. Procedia Manufacturing, 4, 461–470. https://doi.org/10.1016/j.promfg.2015.11.063 30. Naboureh, K., & Safari, E. (2016). Integrating the Sequence Dependent Setup Time Open Shop Problem and Preventive Maintenance Policies. Decision Science Letters, 5 (4), 535–550. https://doi.org/10.5267/j.dsl.2016.4.002 31. Nallusamy, S., & Majumdar, G. (2017). Enhancement of Overall Equipment Effectiveness Using Total Productive Maintenance in a Manufacturing Industry. International Journal of Performability Engineering, 13 (2), 173–188. https://doi.org/10.23940/ijpe.17.02.p7.173188 32. OECD. (2010-2022). OECD Science, Technology and Innovation Scoreboard. Retrieved from https://www.oecd.org/sti/scoreboard.htm 33. Otero, E., & Lopes, I. (2018). Productivity Improvement of a Production Line through Quick Changeover Concept - A Case Study. Advances in Transdisciplinary Engineering, 7 (1), 897–906. https://doi.org/10.3233/978-1-61499-898-3-897 34. Pattaro Jr., R. G., Inácio, R. H., Da Silva, I. B., Hassui, A., & Barbosa, G. F. (2022). A Novel Framework for Single‑Minute Exchange of Die (SMED) Assisted by Lean Tools. International Journal of Advanced Manufacturing Technolog y, 119, 6469–6487. https://doi.org/10.1007/s00170-021-08534-w 35. Petrillo, A., Felice, F. D., & Zomparelli, F. (2018). Performance Measurement for World-Class Manufacturing. Total Quality Management & Business Excellence, 30 (7-8), 908–935. https://doi.org/10.1080/14783363.2017.1408402 36. Pinto, G., Silva, F. J. G., Fernandes, N. O., Casais, R., Baptista, A., & Carvalho, C. (2020). Implementing a Maintenance Strategic Plan Using TPM Methodology. International Journal of Industrial Engineering and Management, 11 (30), 192–204. http://doi.org/10.24867/IJIEM-2020-3-264 37. Poor, P., Basl., J., & Ženíšek, D. (2020). Assessing the Predictive Maintenance Readiness of Enterprises in West Bohemian Region. Procedia Manufacturing, 42, 422–428. https://doi.org/10.1016/j.promfg.2020.02.098 38. Pribeanu, G., & Toader, C. S. (2016). The Success in Business in the Context of Sustainable Development. Agricultural Management, 18 (2), 99–102. Retrieved from http://bit.ly/30an6Yw 39. Rajnoha, R., Dobrovic, J., & Gálová, K. (2018). The Use of Lean Methods in Central Eastern European Countries: The Case of Czech and Slovak Republic. Economics & Sociolog y, 11 (2), 320–333. https://doi.org/10.14254/2071-789X.2018/11-2/22 40. Rathi, R., Singh, M., Sabique, M., Al Amin, M., Saha, S., & Krishnaa, M. H. (2022). Identification of Total Productive Maintenance Barriers in Indian Manufacturing Industries. Materials Today: Proceedings, 50 (5), 736–742. https://doi.org/10.1016/j.matpr.2021.05.222 41. Ribeiro, M. A. S., Santos, A. C. O., de Amorim, G. F., de Oliveira, C. H., da Silva Braga, R. A., & Netto, R. S. (2022). Analysis of the Implementation of the Single Minute Exchange of Die Methodology in an Agroindustry through Action Research. Machines, 10, 287. https://doi.org/10.3390/machines10050287 42. Rosa, C., Silva, F. J. G., Ferreira, L. P., & Campilho, R. (2017). SMED Methodology: The Reduction of Setup Times for Steel Wire-Rope Assembly Lines in the Automotive Industry. Procedia Manufacturing, 13, 1034–1042. https://doi.org/10.1016/j.promfg.2017.09.110 43. Rylková, Ž., Čemerková, Š., & Pokorná, P. (2021). Key Indicators of the Production Process in Global Environment. SHS Web of Conferences, 92, 03025. https://doi.org/10.1051/shsconf/20219203025 44. Říha, A., Pěchouček, M., Vokřínek, J., & Mařík, V. (2002). From Intra-Enterprise towards Extra-Entreprise Production Planning. In V. Mařík, L. M. Camarinha-Matos, & H. Afsarmanesh, Knowledge and Technology Integration in Production and Services. Springer. https://doi.org/10.1007/978-0-387-35613-6_39 45. Salam, M. A., & Khan, S. A. (2018). Achieving Supply Chain Excellence through Supplier Management. Benchmarking: An International Journal, 25 (9), 4084–4102. https://doi.org/10.1108/BIJ-02-2018-0042 46. Sangwan, K. S., Bhamu, J., & Mehta, D. (2014). Development of Lean Manufacturing Implementation Drivers for Indian Ceramic Industry. International Journal of Productivity and Performance Management, 63 (5), 569–587. https://doi.org/10.1108/IJPPM-06-2013-0105 47. Saravanan, V., Nallusamy, S., & Balaji, K. (2018). Lead Time Reduction through Execution of Lean Tool for Productivity Enhancement in Small Scale Industries. International Journal of Engineering Research in Africa, 34, 116–127. https://doi.org/10.4028/www.scientific.net/JERA.34.116 48. Singh, R. K., & Gurtu, A. (2021). Prioritizing Success Factors for Implementing Total Productive Maintenance (TPM). Journal of Quality in Maintenance Engineering, ahead-of-print. https://doi.org/10.1108/JQME-09-2020-0098 49. Singh, S., Kiran, R., & Goyal, D. (2015). Identification of Key Factors for Enhancing Competitiveness: An Exploratory Study of the Selected Agri-Biotech Firms of Punjab in India. Agricultural Economics, 61 (4), 179–188. https://doi.org/10.17221/26/2014-AGRICECON 50. Singh, J., & Singh, H. (2015). Continuous Improvement Philosophy. Benchmarking: An International Journal, 22 (1), 75–119. https://doi.org/10.1108/BIJ-06-2012-0038 51. Singh, M., Singh, K., & Sethi, A. S. (2022). Contribution of Green Manufacturing for Realizing Business Performance in Indian Small and Medium Scale Organizations. Journal of Science and Technolog y Policy Management, 13 (2), 329–357. https://doi.org/10.1108/JSTPM-11-2020-0163 52. Slaichova, E., & Marsikova, K. (2013). The Effect of Implementing a Maintenance Information System on the Efficiency of Production Facilities. Journal of Competitiveness, 5 (3), 60–75. https://doi.org/10.7441/joc.2013.03.05 53. Suryaprakash, M., Gomathi Prabha, M., Yuvaraja, M., & Rishi Revanth, R. V. (2021). Improvement of Overall Equipment Effectiveness of Machining Centre Using TPM. Materials Today: Proceedings, 46 (19), 9348–9353. https://doi.org/10.1016/j.matpr.2020.02.820 54. Thuis, P., & Stuive, R. (2019). Business Administration. Groningen: Routledge. 55. Tomaskova, Y., & Strakova, A. (2015). Alternative Ways to Provide the Maintenance in Czech Coal Power Plants. Surveying Geolog y & Mining Ecolog y Management, 1, 569–576. Retrieved from http://bit.ly/2MniVW1 56. Tsarouhas, P. (2019). Improving Operation of the Croissant Production Line through Overall Equipment Effectiveness (OEE): A Case Study. International Journal of Productivity and Performance Management, 68 (1), 88–108. https://doi.org/10.1108/IJPPM-02-2018-0060 57. Tyagi, S., Choudhary, A., Cai, X., & Yang, K. (2015). Value Stream Mapping to Reduce the Lead-Time of a Product Development Process. International Journal of Production Economics, 160 (1), 202–212. https://doi.org/10.1016/j.ijpe.2014.11.002 58. Udokporo, C. K., Anosike, A., Lim, M., Nadeem, S. P., Garza-Reyes, J. A., & Ogbuka, C. P. (2020). Impact of Lean, Agile and Green (LAG) on Business Competitiveness: An Empirical Study of Fast Moving Consumer Goods Businesses. Resources, Conservation and Recycling, 156, 104714. https://doi.org/10.1016/j.resconrec.2020.104714 59. United Nations. (2020). Value Added by Economic Activity, at constant 2015 prices. Retrieved from https://unstats.un.org/unsd/snaama/Basic 60. Ylipää, T., Skoogh, A., Bokrantz, J., & Gopalakrishnan, M. (2017). Identification of Maintenance Improvement Potential Using OEE Assessment. International Journal of Productivity and Performance Management, 66 (1), 126–143. https://doi.org/10.1108/IJPPM-01-2016-0028 61. Zammori, F., Braglia, M., & Frosolini, M. (2011). Stochastic Overall Equipment Effectiveness. International Journal of Production Research, 49 (21), 6469–6490. https://doi.org/10.1080/00207543.2010.519358
utb.fulltext.sponsorship	The authors would like to thank the Internal Grant Agency of FaME TBU in Zlín for providing financial support to carry out this research. Funding was extended through TBU in Zlín No. IGA/FaME/2019/007/ Increasing Business Competitiveness by Meeting Customer Requirements in Customer Relationship Management Using Industrial Engineering Tools.
utb.wos.affiliation	[Ondra, Pavel] Tomas Bata Univ Zlin, Fac Management & Econ, Dept Ind Engn & Informat Syst, Zlin, Czech Republic
utb.scopus.affiliation	Tomas Bata University in Zlín, Faculty of Management and Economics, Department of Industrial Engineering and Information Systems, Czech Republic
utb.fulltext.projects	IGA/FaME/2019/007
utb.fulltext.faculty	Faculty of Management and Economics
utb.fulltext.ou	Department of Industrial Engineering and Information Systems