Reduction of SETUP Time, Applying SMED Methodology in the Mold Change in the PVC Plastic Pipe Production Process

A plastic manufacturing company in Durán has problems reducing SETUP time in changing molds in the production process of PVC plastic pipe. Thus, through this research work, the SMED methodology was implemented, which allowed optimizing and standardizing the activities related to mold changes, eliminating unnecessary steps and simplifying the processes, improving the company’s efficiency, productivity, and responsiveness in the PVC pipe extrusion process. Thus, the company presented a strategic and focused response to the challenges inherent in the production process. After analyzing the initial situation of all the extrusion lines (14 in total), the SMED methodology was applied in the XT-07 (extruder 07, XT is the nomenclature for the extrusion lines), which had the most extended SETUP times, where improvements were used at the time of serial changeover, which went from 71 to 33 min of machine stoppage, and a total time from 123 to 113 min. In addition, a cultural change has been achieved in the organization, encouraging collaboration and active participation of the teams in continuous improvement. The standardization and simplification of processes not only benefit the extrusion process itself but also extend to other aspects of the operation. They promote a mindset of efficiency and adaptability, allowing the company to adjust quickly to new production orders and specific customer requirements.