Our Changeovers Take Too Long
Long changeovers cost twice. The machine sits while it is set up, and the shop runs bigger batches to avoid setups, which adds WIP and lead time. SMED is the method, and it starts with a video and a stopwatch, not a capital request.
What Is Usually Going On
- Setup work that could be done while the machine runs is done while it is stopped.
- Tools, fixtures, programs and material are hunted for during the setup.
- Adjustments and trial parts after the setup take longer than the setup itself.
- No standard sequence, so every setup is done differently.
How to Fix It
- Film one changeoverFrom last good part to first good part at rate. Watch it with the people who do it.
- List every elementEach step with its time, marked internal (machine must be stopped) or external (can be done while it runs).
- Move external work outStaging, tool carts, preheat and program loads all happen before the machine stops.
- Convert internal to externalPreset tools and fixtures offline, standard heights, quick connects.
- Streamline the restFixed locators instead of adjustment, fewer bolts and turns, two people in parallel on long setups.
- Write it downA standard changeover sequence and checklist, then time the next several to confirm it holds.
Start Free
Guides and web tools on this site. No account needed.
When It Moves to the Floor
The same work as an offline file you keep: saved scenarios, print and export, no internet needed on the floor.
Common Questions
What does SMED stand for?
Single minute exchange of die: the goal of changeovers under ten minutes. The method works for any setup: a test stand between units, a pack line between SKUs, a bay between aircraft or vehicles.
Where do we start?
On the constraint machine, or the machine where long setups push the shop into big batches.
Does SMED need new equipment?
Rarely at first. Early gains come from moving work outside the stop and getting organized. Spend on quick connects after the sequence is fixed.
What do we do with the hours we free up?
On the constraint: more output. Elsewhere: more changeovers and smaller batches, which cut WIP and lead time.