SMED (Single Minute Exchange of Dies)

SMED refers to a theory and the techniques for performing set-up operations in under ten minutes, the number of minutes expressed in a single digit. We will discuss that while not all set-ups can be reduced to less than ten minutes, they can all be improved.


Program Highlights

  • How SMED relates to Just In Time (JIT) - Small Lot Production
  • Definition of Terms
  • Four Stages of SMED
  • Set-up Improvement
  • Actions to convert Internal to External time
  • Techniques to improve internal set-up time


Preparation Phase

During the 3 days on site for preparation, our facilitator accomplishes the following:

  • Observation of manufacturing and changeover activities
  • Prepare changeover process flow chart
  • Creation / modification of changeover standard procedures
  • Video tape a minimum of two changeovers for use in the SMED class
  • Prepare other documentation as required
  • Work with management to pick and notify training participants



In the time between the preparation phase and training class, PPIG prepares a step-by-step analysis of the changeover. This information is included in the participant's manuals that are a part of the SMED training.


Training Course Phase

During the 4 and 1/2 days that the team is together, we go through the training course, review the videotape, and document the activities needed to improve the set-up. The team then spends the rest of the time making physical changes that will enable the changeover crew to complete the set-up 50% faster than your current change process. All improvements are documented and presented to the management team on the morning of the 5th day.


Changeover Matrix

As it suggests this incorporates the use of Matrix techniques to determine the frequency and length of changeovers giving the following benefits:

  • Benchmark for Improvement (Time & Frequency)
  • Opportunity to compare like machines
  • Standardise Changeover Process
  • Identify Priority Work
  • Aid Capital Expenditure Planning

PPIG would carry out this as part of the preparation stage of the SMED training workshop and would form part of the process when it came to updating following improvement.


Cycle Scheduling

Cycle Scheduling involves the integration of planning information and the most economical/ efficient changeover matrix. The combined effect is a recognised Cycle for the reviewed area/work stream that can deliver considerable savings, not only via reduced changeover times but also by including the elements of a Planned Preventative Maintenance Program in the Cycle.