SMED, Quick Changeover, Setup Reduction. OPEX Minute 16 Presented by EMS Consulting Group, Inc.:

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Welcome to today’s edition of the OpEx Minute, presented by EMS Consulting Group. Today we will be talking about Single Minute Exchange of Die or SMED, a widely used tool within the Lean framework.
Single Minute Exchange of Die (SMED), or Quick Changeover, is a method developed by industrial engineering consultant Shigeo Shingo to reduce changeover time on machines. Changeover time is defined as the time between the last good part produced from one run and the first good part produced from the next run. SMED is considered a key tool for implementing flow and pull systems within the Toyota Production System, because it both reduces and standardizes setup time.
Shingo’s time studies proved that his quick changeover methodology will work on any machine. Application of the system reduces setup from hours to minutes. The goal is to utilize this flexibility to create continuous flow and leveled production
Shingo’s SMED system includes three stages:
Stage 1: Separate internal and external setup steps — After detailed observation of the current process’ documentation, classify each step in the changeover. If the machine must be stopped for the step to occur, then we classify the step as internal. Otherwise, the step is external.
Stage 2: Convert internal to external — Examine the true function of internal setup operations and find ways to externalize these. Some solutions include modification of tooling, purchasing off-the-shelf solutions for externalizing setup, and other customized solutions.
Stage 3: Streamline all aspects of the setup operation, whether internal or external — Perform a detailed analysis of each work element, and then eliminate waste from each step.
Applying SMED or quick changeover to setups is a great way to become more flexible and level output. Leveling work is an important concept, and we will be talking about this in a future OPEX Minute. If you have an interest in learning more about Quick changeover, visit our website at www.emsstrategies.com and contact us. We would be happy to help.

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