Calculate Changeover Time Reduction with SMED
Separate internal and external setup tasks, set a target internal time, and see the financial impact of faster changeovers on your production line.
Current Changeover
Machine must be stopped
Can be done while running
SMED Target
Reduced internal time after converting tasks to external
Production Schedule
Internal time reduction: 45 min → 20 min = 56% reduction
Annual Savings
$32,500
projected per year
Time Saved per Changeover
25 min
Weekly Time Savings
4.2 hrs
Cost Comparison
Weekly Cost Savings
$625
per week
Additional Capacity
217 hrs
per year
What is SMED?
SMED (Single-Minute Exchange of Die) is a lean manufacturing method developed by Shigeo Shingo that systematically reduces changeover time. The goal is to complete as much setup work as possible while the machine is still running, then streamline the remaining tasks that require the machine to be stopped.
Tasks that can only be performed when the machine is shut down. Examples include changing dies, adjusting fixtures, and swapping tooling. SMED aims to minimize these by converting as many internal tasks as possible to external ones.
Tasks that can be performed while the machine continues to run. Gathering tools, pre-staging materials, preheating dies, and preparing paperwork are common examples. Moving more tasks here is the fastest way to cut changeover time.
The Four Stages of SMED
SMED follows a structured approach to systematically reduce changeover time. Each stage builds on the previous one.
Observe and Document
Video record the entire changeover. Document every step, who performs it, and how long it takes. Most teams discover 30-50% of changeover time is wasted on searching, walking, or waiting.
Separate Internal and External
Classify every task as internal (machine stopped) or external (machine running). This step alone often reduces changeover time by 30-50% with minimal investment.
Convert Internal to External
Find ways to perform internal tasks while the machine runs. Pre-heat dies, pre-stage tools at the machine, use duplicate fixtures, and prepare settings in advance.
Streamline All Tasks
Eliminate adjustments with standardized settings. Replace bolts with quick-release clamps. Use parallel operations where two people work simultaneously. Target single-minute (under 10 minutes) changeovers.
SMED Implementation Tips
Practical advice for getting results from your SMED initiative.
Start Here
- 1.Pick your longest or most frequent changeover first
- 2.Video record it from start to finish without interrupting
- 3.Involve operators in the analysis, not just engineers
- 4.Create a changeover checklist with pre-staging requirements
Common Quick Wins
- 1.Stage all tools and materials at the machine before stopping
- 2.Replace bolts with quick-release clamps or toggle fasteners
- 3.Use color-coded marks and standardized settings to eliminate trial runs
- 4.Assign parallel tasks so two people work simultaneously during the stop