Quick Changeover (SMED)

Quick Changeover / SMED (Single Minute Exchange of Dies) / Set-up Reduction, reduces the time it takes to change from one product to another and therefore reduces process downtime.

Quick Changeover is a systematic approach that enables organisations to build on the principles developed by Shigeo Shingo, a Japanese industrial engineer who was extraordinarily successful in helping companies dramatically reduce their changeover times. His pioneering work led to documented reductions in changeover times averaging 94% (e.g. from 90 minutes to less than 5 minutes) across a wide range of companies.

Since set-up activities add no marketable form, fit, or function to the product, they are by definition non-value adding. By reducing set-up time, more set-ups can be completed each day allowing batch size reduction, which is critical for flow and improves manufacturing flexibility.

Can my business benefit from SMED ?

Virtually every manufacturing company that performs changeovers can benefit from SMED. That does not mean, however, that SMED should be the first priority. Companies have finite resources, and those resources should be directed to where they will generate the best return. So the first priority should be ensuring that there is a clear understanding of where productive time is being lost, and that decisions on improvement initiatives are made based on hard data. That means putting a system in place to collect and analyse manufacturing performance data.

If changeovers represent a significant percentage of lost productive time (e.g. at least 20%) we would recommend proceeding with a SMED programme, otherwise, consider first focusing on a TPM (Total Productive Maintenance).

This 1-day Lean Training workshop introduces participants to the tools and techniques of set-up reduction, providing the learner with a simple and structured methodology for analysing and improving machine changeovers, that will result in concrete improvement actions and through standardisation, ensure sustainability of drastically reduced changeover times.

If required BTA can incoporate a post course assignment approach following this training when we will facilitate, coach and support the team in the application of their newly developed skills.

Check upcoming Lean Training events for dates and venues or contact us for further details