The 4 Stages of SMED Implementation
1. Document current changeover via video. 2. Separate internal from external steps. 3. Convert internal steps to external. 4. Streamline all remaining steps via quick-clamping and standard tooling.
Intermediate Category: Lean & Continuous Flow • ~6 min read
SMED Quick Changeover Analyzer
Slash machine changeover downtime by converting internal steps to external preparations.
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Q:
What is Single-Minute Exchange of Die (SMED)?
Developed by Shigeo Shingo, SMED aims to reduce manufacturing equipment changeover times to single digits (under 10 minutes). The core breakthrough is separating Internal Setup (tasks that can only be done while stopped) from External Setup (tasks done while running).
Current Machine Downtime105 minInternal Setup Tasks
Target SMED Downtime47 minPost-Conversion Goal
Potential Time Saved58 minInternal → External Shifts
Downtime Reduction55.2%Capacity Unlocked
Changeover Tasks Breakdown (Shigeo Shingo SMED Methodology)Check tasks that can be performed while machine is still running
Retrieve new die & bolts from tooling room18 minutes
Loosen clamp bolts and unseat previous die12 minutes
Hoist old die out and place on storage rack15 minutes
Position new die and hand-align guide pins20 minutes
Preheat mold heaters to operating temp25 minutes
Perform test run and measure first-article15 minutes
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