Setup Time Reduction of an Automotive Parts Assembly Line Using Lean Tools and Quality Tools

The business world is becoming more competitive. Therefore, it crucial to increase the flexibility of production by decreasing time used in processes preparing lines for new items’ production, reducing changeover and setup times. This paper presents a case study where main goal reduce welding robots. Single Minute Exchange Die (SMED) was implemented, using other tools such as Spaghetti Diagram, ERCS Analysis (Eliminate, Rearrange, Combine, Simplify), Gemba Walk, Standardized Work, Flowcharts, Pareto Diagram. decreased 36% robots studied, motions 43% during process from categories: “transportation”, “main”, “other”, “waiting”. In addition SMED implementation, this offers an integrated several Lean Quality achieve maximum reduction