Quick Changeover

Basics

SMED
Definition of Changeover Time
• The time between
the last good
piece off the
current run and
the first good
piece off the next
run.
 Traditional Changeover
Before improvements, basic setup tasks and related time
breakdowns:

Percent of time of changeover Preparation, after-process

adjustment, checking, storing, and
moving materials, parts, and tools

30%
Removing and mounting parts
and tools
50%

5% Machine measurements, settings,

15% and calibrations

Trial runs and adjustments

The Best Changeover is

No Changeover
Traditional Changeover and the Wastes of Lean

Traditional Changeover Tasks

Preparation Removing Measurements Trial Runs
and and , Settings, and
Adjustments Mounting Calibrations Adjustments

Overproduction

Waiting

Transportation

Processing

Inventory

Defects

Motion

People
Changeover Improvement Process
Document

Analyze
Lean Basics
Standardize

Implement
 Traditional Changeover

Hours

Day 1 Day 2 Day 3 Day 4 Day 5

 Traditional Changeover
2-Hour Changeover (CO)

Weekly CO time: 10 hours

Hours Run time: 30 hours

Available time: 0 hours

A B C D E

2 hours 2 hours 2 hours 2 hours 2 hours

Day 1 Day 2 Day 3 Day 4 Day 5

Quick Changeover

3-Minute Changeover

Hours

Day 1 Day 2 Day 3 Day 4 Day 5

Quick Changeover

3-Minute Changeover

A A A A A

B B B B B Weekly CO time: 75 minutes

Hours Run time: 30 hours

C C C C C
Available time: 8.75 hours

D D D D D

E E E E E
Day 1 Day 2 Day 3 Day 4 Day 5
What Does Quick Changeover
Involve?
• Planning

• Practice

• Innovation

• Standardization

• Continuous
Improvement
 Impact of Quick Changeover
Improved On-Time
Delivery

Flexible Response
to Customer Needs

Reduced Lead
Time

Decreased Costs,
Increased Capacity

Increased Accuracy,
Improved Quality
 Document the Current Changeover

Document • Document all the tasks

or elements that make
up the current
changeover
Analyze
Lean Basics
SMED
Standardize
• Capture and visually
organize data about the
changeover
Implement

• Identify changeover
improvement priorities
 How Do We Improve
• A systematic approach is needed
• Single Minute Exchange of Die (SMED)
• Developed in the 1950’s in Japan
• The goal is to get every changeover under
10 minutes (single digit)
• You can not get there in one step or one
event
The SMED Approach

• Identify internal vs.

external changeover
tasks
• Analyze each task’s
real purpose and
function
• Focus on no/low cost
solutions
• Aim to eliminate
changeover time
Three Stages of SMED
• Separate Internal and
External Setup

• Convert Internal Setup

to External Setup

• Streamline Internal and

External Elements

Setup Reduction
 SMED: Separate Internal and External Setup
• Separate Internal and
External Setup • Develop and implement
changeover checklists.

• Convert Internal Setup

to External Setup • Perform function
checks on parts and
tools.
• Streamline Internal and
External Elements • Reduce transportation
of tools, parts, and
materials.
Setup Reduction
 SMED: Separate Internal and External Setup
Develop and Implement Changeover Checklists

• Develop specific checklists for every piece

of equipment and major process.
- What is needed?
- Where is it needed?
- Who needs to do what?
- How long should it take?
- What are the proper operating
conditions?
- What are the correct settings for the next
operation?

• Keep checklists up-to-date and visible to all.

 SMED: Separate Internal and
Perform FunctionExternal
Checks on PartsSetup
and Tools

• Are all of the changeover materials in

good working order?
- Tools
- Parts
- Jigs
- Fixtures

• Have all materials been checked far

enough in advance to allow time for
repairs?
 SMED: Separate Internal and External Setup
Reduce Transportation of Tools, Parts, and Materials

• Reduce non-value added movement of

changeover parts, tools, and materials

• Transport changeover materials before the

machine shuts down

• Focus on no/low cost solutions

No/Low Cost Solution: Reduce Transportation
SMED: Convert Internal Setup to External Setup

• Separate Internal and

External Setup
• Prepare operating conditions
in advance
• Convert Internal Setup
to External Setup • Standardize functions

• Use intermediary jigs

• Streamline Internal and
External Elements

Setup Reduction
 SMED: Convert Internal Setup to External Setup
Prepare Operating Conditions in Advance

• Preheat parts and tools to required

temperature before they are needed

• Achieve correct pressure levels before

start-up

• Position materials near point-of-use

SMED: Convert Internal Setup to External Setup
Standardize Functions

• Eliminate time-consuming adjustments

• Focus on functions such as

dimensioning, securing, gripping, and
centering

• Replace the fewest possible parts by

changing the way we perform the
function
No/Low Cost Solution: Standardize Functions

Die Plate Adjusts

Shut Height
SMED: Convert Internal Setup to External Setup
Use Intermediary Jigs

• Design and build standard-sized,

removable plates or frames

• Externally attach and adjust die/parts

• Eliminate internal adjustments to

individual parts during changeover
SMED: Streamline Internal and External Elements
• Separate Internal and
External Setup
• Implement parallel operations
• Convert Internal Setup • Eliminate the need for
to External Setup adjustments

• Use functional clamps

• Streamline Internal and • Mechanize functions
External Elements

Setup Reduction
 SMED: Streamline Internal Elements
Implement Parallel Operations

• Divide changeover tasks between two or

more people.

• Maintain detailed changeover

procedures.
- Who’s doing what?
- Sequence of tasks
- Required time for each task

• Reduce wasted motion, avoid confusion,

and ensure worker safety.
 SMED: Streamline Internal
Elements
Eliminate the Need for Adjustments

• Use visual marks to indicate correct

settings

• Create “quick set” mechanisms to

handle different functions

• Install fixed stops to indicate where a

part should be positioned
No/Low Cost Solution: Use of
Numerical Scales

Numerical Scale
 No/Low Cost Solution: Use of
Positioning Pins
Positioning Pins

Positioning Pins
 Setup Reduction Tools

• Cartridges

• Standard work (dance cards)

• Quick release handles

• Off line setups

• Water spider (pit crew)

• Setup documentation

• Improved machine reliability

 SMED: Streamline Internal
Use Functional ClampsElements

• One-turn methods

• One-motion methods

• Interlocking methods
No/Low Cost Solution: One-Turn Methods

Pear-Shaped Hole Method

Tighten Here

Attach and
Remove
Here
No/Low Cost Solution: One-Turn Methods

Wing Nut Method

No/Low Cost Solution: One-Motion
Methods
Cam Method
 SMED: Streamline Internal Elements
Mechanize Functions

• Use to fine tune, not significantly reduce,

setups

• Consider only when changeover reaches

the three-minute range

• Focus on no/low cost solutions

 SMED: Streamline External Elements
• Separate Internal and
External Setup

• Convert Internal Setup

to External Setup Maintain a Visual,
Organized Workplace

• Streamline Internal and

External Elements

Setup Reduction
Three Stages of SMED
• Separate Internal and
External Setup

• Convert Internal Setup

to External Setup

• Streamline Internal and

External Elements

Setup Reduction
Analyze Changeover Tasks and Identify Improvements
Analyze

Document • Distinguish between internal

and external setup tasks.

• Identify and apply proven

techniques to convert
Lean Basics
Analyze internal to external setup
Standardize
SMED tasks.

• Develop streamlined
processes for internal and
external setup tasks.
Implement

• Create an improved
changeover process.
 Applying SMED
Analyze Changeover Tasks
Identify Improvements
• Complete Setup Analysis
Chart.

• Develop no/low cost

solutions.

• Streamline, streamline,
streamline!

• Create an improved
changeover process.
Implement Improvements and Monitor Results
Implement

Document

• Implement Quick
Changeover
Analyze
improvements
Lean Basics
SMED
Standardize

• Monitor and
document results

Implement
 Standardize the Improvements
Standardize

Document

Analyze
• Develop a plan to
Lean Basics
SMED standardize
Standardize
improvements

Implement
Benefits of Quick Changeover
Improved On-Time
Delivery

Flexible Response
to Customer Needs

Reduced Lead
Time

Decreased Costs,
Increased Capacity

Increased Accuracy,
Improved Quality