• Atharva Amrutkar
• Dr. Harshada Mulay

This study investigates the application of Single-Minute Exchange of Die (SMED) techniques to minimize grade changeover time in twin-screw extruders used in polymer processing. High changeover time lead to production inefficiencies and increased costs in the competitive landscape of plastic manufacturing. A case study was conducted at a polymer extrusion facility to analyse the existing grade changeover process, identify bottlenecks, and implement SMED principles. This research explores various SMED techniques applicable to polymer extrusion, including preheating dies, standardizing cleaning procedures, and utilizing quick-release mechanisms. By converting internal setup activities (performed during machine stoppage) into external setups (Executed during machine operation) and streamlining remaining internal activities, these initiatives led to considerable decreases in changeover time. This study contributes to the body of knowledge on Lean manufacturing in polymer processing and provides practical insights for industry practitioners. These findings demonstrate the potential of SMED techniques in addressing the persistent challenge of lengthy grade changes in polymer extrusion, ultimately contributing to Enhanced production efficiency and lowered industry costs.

Lean Manufacturing, Single-Minute Exchange of Die (SMED), Polymer Extrusion, Grade Changeover, Twin-Screw Extruder, Operational Efficiency, Process Optimization, Operational Efficiency, Quick-Release Mechanisms, Standardization, Internal Setup Activities, Production Efficiency, Waste Reduction, Overall Equipment Effectiveness (OEE)

"Lean Manufacturing in Polymer Extrusion: SMED Techniques for Minimizing Grade Changeover Time", International Journal of Emerging Technologies and Innovative Research (www.jetir.org), ISSN:2349-5162, Vol.12, Issue 1, page no.f150-f157, January-2025, Available :http://www.jetir.org/papers/JETIR2501515.pdf

"Lean Manufacturing in Polymer Extrusion: SMED Techniques for Minimizing Grade Changeover Time", International Journal of Emerging Technologies and Innovative Research (www.jetir.org | UGC and issn Approved), ISSN:2349-5162, Vol.12, Issue 1, page no. ppf150-f157, January-2025, Available at : http://www.jetir.org/papers/JETIR2501515.pdf