Industry 4.0-Enabled SMED Implementation for Improving Pipe Extrusion Efficiency: A Case Study

Efficient equipment utilization is critical in the competitive plastics industry, where prolonged setup and changeover times, particularly in die-changing processes, impede productivity and delay order fulfillment, leading to customer dissatisfaction. This study addresses these challenges by implementing Single Minute Exchange of Die (SMED), a key Industry 4.0 methodology, to optimize setup processes in pipe extrusion. SMED systematically identifies and segregates internal (machine-stopped) and external (machine-running) setup activities, aiming to minimize overall setup time. By streamlining workflows and adopting best practices, SMED demonstrates substantial benefits in pipe manufacturing, which often requires frequent die changes. A case study revealed that the initial die setup process required 50 minutes and six workers. Through SMED implementation, this time was reduced to 20 minutes - a 60% improvement. Learning curve analysis further validated this reduction, illustrating how consistent practice and process refinement achieved the target setup time efficiently. These improvements resulted in a 40% productivity gain and annual cost savings of 518,400 taka (4,320 USD). This research highlights the transformative potential of Industry 4.0 tools like SMED in optimizing setup times, enhancing productivity, reducing bottlenecks, and maximizing equipment utilization, thereby significantly improving operational efficiency and competitiveness in the pipe extrusion industry. Keywords: SMED, Industry 4.0, Smart Manufacturing, Setup Optimization, Productivity Improvement