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Circular Economy Optimization of SMED Changeovers for Energy-Efficient Sustainable Automotive Manufacturing Systems.

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Title: Circular Economy Optimization of SMED Changeovers for Energy-Efficient Sustainable Automotive Manufacturing Systems.
Authors: Lewicki, Wojciech1 (AUTHOR) mikulik@agh.edu.pl, Niekurzak, Mariusz2 (AUTHOR), Miązek, Paweł3 (AUTHOR), Wyszomirski, Adam4 (AUTHOR), Mikulik, Jerzy1,2 (AUTHOR)
Source: Energies (19961073). Apr2026, Vol. 19 Issue 7, p1732. 29p.
Subject Terms: *Setup time, *Energy consumption, *Sustainability, *Automobile industry, *Process optimization, *Circular economy
Abstract: This study investigates the application of the SMED (Single-Minute Exchange of Die) methodology to improve operational efficiency and support energy- and resource-efficient manufacturing systems. The research is based on a case study conducted in an automotive company producing electrical harnesses, where SMED was implemented to optimize changeover processes and reduce process-related inefficiencies. The methodological approach follows an AS-IS to TO-BE framework, incorporating direct observation, time measurements, and the classification of activities into internal and external operations. In addition to operational indicators, selected energy- and resource-related aspects such as energy consumption during changeovers, material usage, and waste generation were evaluated based on process observation and indirect estimation. The results indicate a significant reduction in changeover time, along with improvements in machine availability and production flow. Furthermore, the study suggests a reduction in process-related energy consumption and material intensity associated with improved organization and reduced downtime, although these effects are partially indirect. The findings demonstrate that SMED can enhance operational efficiency and indicate its potential to improve energy performance in manufacturing systems, primarily through reduced machine downtime and more stable production flows. However, the results are case-specific, and further research based on direct energy measurements and broader industrial applications is required to confirm their generalizability. [ABSTRACT FROM AUTHOR]
Database: Energy & Power Source
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Header DbId: enr
DbLabel: Energy & Power Source
An: 192959136
AccessLevel: 6
PubType: Academic Journal
PubTypeId: academicJournal
PreciseRelevancyScore: 0
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  Label: Title
  Group: Ti
  Data: Circular Economy Optimization of SMED Changeovers for Energy-Efficient Sustainable Automotive Manufacturing Systems.
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  Data: <searchLink fieldCode="AR" term="%22Lewicki%2C+Wojciech%22">Lewicki, Wojciech</searchLink><relatesTo>1</relatesTo> (AUTHOR)<i> mikulik@agh.edu.pl</i><br /><searchLink fieldCode="AR" term="%22Niekurzak%2C+Mariusz%22">Niekurzak, Mariusz</searchLink><relatesTo>2</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Miązek%2C+Paweł%22">Miązek, Paweł</searchLink><relatesTo>3</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Wyszomirski%2C+Adam%22">Wyszomirski, Adam</searchLink><relatesTo>4</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Mikulik%2C+Jerzy%22">Mikulik, Jerzy</searchLink><relatesTo>1,2</relatesTo> (AUTHOR)
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  Data: <searchLink fieldCode="JN" term="%22Energies+%2819961073%29%22">Energies (19961073)</searchLink>. Apr2026, Vol. 19 Issue 7, p1732. 29p.
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  Data: *<searchLink fieldCode="DE" term="%22Setup+time%22">Setup time</searchLink><br />*<searchLink fieldCode="DE" term="%22Energy+consumption%22">Energy consumption</searchLink><br />*<searchLink fieldCode="DE" term="%22Sustainability%22">Sustainability</searchLink><br />*<searchLink fieldCode="DE" term="%22Automobile+industry%22">Automobile industry</searchLink><br />*<searchLink fieldCode="DE" term="%22Process+optimization%22">Process optimization</searchLink><br />*<searchLink fieldCode="DE" term="%22Circular+economy%22">Circular economy</searchLink>
– Name: Abstract
  Label: Abstract
  Group: Ab
  Data: This study investigates the application of the SMED (Single-Minute Exchange of Die) methodology to improve operational efficiency and support energy- and resource-efficient manufacturing systems. The research is based on a case study conducted in an automotive company producing electrical harnesses, where SMED was implemented to optimize changeover processes and reduce process-related inefficiencies. The methodological approach follows an AS-IS to TO-BE framework, incorporating direct observation, time measurements, and the classification of activities into internal and external operations. In addition to operational indicators, selected energy- and resource-related aspects such as energy consumption during changeovers, material usage, and waste generation were evaluated based on process observation and indirect estimation. The results indicate a significant reduction in changeover time, along with improvements in machine availability and production flow. Furthermore, the study suggests a reduction in process-related energy consumption and material intensity associated with improved organization and reduced downtime, although these effects are partially indirect. The findings demonstrate that SMED can enhance operational efficiency and indicate its potential to improve energy performance in manufacturing systems, primarily through reduced machine downtime and more stable production flows. However, the results are case-specific, and further research based on direct energy measurements and broader industrial applications is required to confirm their generalizability. [ABSTRACT FROM AUTHOR]
PLink https://search.ebscohost.com/login.aspx?direct=true&site=eds-live&db=enr&AN=192959136
RecordInfo BibRecord:
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      – Type: doi
        Value: 10.3390/en19071732
    Languages:
      – Code: eng
        Text: English
    PhysicalDescription:
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        PageCount: 29
        StartPage: 1732
    Subjects:
      – SubjectFull: Setup time
        Type: general
      – SubjectFull: Energy consumption
        Type: general
      – SubjectFull: Sustainability
        Type: general
      – SubjectFull: Automobile industry
        Type: general
      – SubjectFull: Process optimization
        Type: general
      – SubjectFull: Circular economy
        Type: general
    Titles:
      – TitleFull: Circular Economy Optimization of SMED Changeovers for Energy-Efficient Sustainable Automotive Manufacturing Systems.
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            NameFull: Lewicki, Wojciech
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            NameFull: Niekurzak, Mariusz
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            NameFull: Miązek, Paweł
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            NameFull: Wyszomirski, Adam
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            NameFull: Mikulik, Jerzy
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            – D: 01
              M: 04
              Text: Apr2026
              Type: published
              Y: 2026
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              Value: 19
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            – TitleFull: Energies (19961073)
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