SMED technique in Flexible Packaging Industry

Posted on 

May 11, 2017

 by admin

The packaging industry in India is expected to reach $ 73 billion in 2020 from $ 32 billion in FY 15,

according to a report prepared by FICCI and Tata Strategic Management Group (TSMG) on plastic industry titled ‘Plastic packaging: The sustainable choice’. In the coming years, Indian packaging industry is anticipated to register 18 percent annual growth rate, with the flexible packaging and rigid packaging expected to grow annually at 25 percent and 15 percent, respectively.

The Indian packaging industry constitutes about 4 percent of the global packaging industry. The per capita packaging consumption in India is quite low at 4.3 kgs, compared to countries like Germany and Taiwan where it is 42 kgs and 19 kgs respectively. However, organized retail and boom in e-commerce, which offer huge potential for future growth of retailing, is giving a boost to the packaging sector

In order to compete with the market requirements, excelling in the core operations to deliver the product in minimum possible time is a challenge for any kind of industry. Since flexible packaging is closely related with e-retailers and FMCG, the responsibility will be more.


Single Minute Exchange of Dies or SMED is a tool developed Shigeo Shingo to reduce the set – up time. He reduced the setup time on a 1000 ton press from 4 hours to 3 minutes. Although primarily developed in automotive industry, SMED is now used world widely for reducing setup and changeover times.

A successful SMED program will have the following benefits:

  • Lower manufacturing cost (faster changeovers mean less equipment down time)
  • Smaller lot sizes (faster changeovers enable more frequent product changes)
  • Improved responsiveness to customer demand (smaller lot sizes enable more flexible scheduling)
  • Lower inventory levels (smaller lot sizes result in lower inventory levels)
  • Smoother startups (standardized changeover processes improve consistency and quality)

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