SMED, Single Minute Exchange of Dies, quick changeovers

SMED, Single Minute Exchange of Dies, quick changeovers - different terms for very similar things.

SMED training towards Lean Six Sigma Certification Reducing Setup Times

SETUP: Work Required To Convert Process from Running One Part or Operation to Running Another.

EXTERNAL SETUP: Work done while the machine is running good parts

INTERNAL SETUP: Work done while the machine is not running good parts

SETUP TIME: Elapsed time from the last good unit of one production run to the first good unit of the next production run.

Standard Setup Activities

Exchanging dies or tools 10%

Positioning dies or tools 20%

Making adjustments 45%

Gathering necessary items 25%

Where is most of the time spent?

Five Steps to Quick Changeover

1. Observe the current process.

2. Differentiate internal & external.

3. Convert internal into external.

4. Streamline internal operations.

5. Streamline external operations.

Step 1. Observe the Current Process


Start machine, wait on machine cycle.

Remove and gauge part, place in bin.

Obtain new parts, place in fixture, start machine.

Step 2. Differentiate Internal and External

Stage all items before shutting down the machine

Develop checklist for needed changeover items

Store high-use items at the machine

Use die charts and tool boards

Use visual management: “on deck circle,” scheduling board

Place tools and parts in order of usage

Check all items to ensure proper fit and function

Sharpen and Preset Tools

Clean Fixtures and Verify Free of Defects

Cleanup & Return Removed Tools After First Good Part

Step 3. Convert Internal to External

Standardize Operations to Minimize Internal Adjustments Die pressures Size and shape Dies, tools, & jigs Bolts, hoses, & handles

Height and Stroke Die height Machine level Handling & storage level

Prepare operating conditions prior to the changeover

Preheat, pre-set, pre-cut, or pre-adjust

Form dress grinding wheels offline

Use intermediary fixtures/jigs

Presetting tools

Positioning dies

Replace fewest parts possible

Position dies or tooling for quick insertion into machine

Step 4. Improve Internal Operations

Eliminate Time Lost Removing and Installing Bolts

Replace bolts with functional clamps

Eliminate all adjustments Graduated scales – Standardized settings Calibrated values – Setting gauges/blocks Measurement devices – Dead stop locations

Motion Element Analysis

Move both hands at the same time

Make two-handed motions brief and small

Maximize use of hands and forearms for light work

Avoid swift changes in direction

Maintain appropriate center of gravity

Step 5. Improve External Operations

Avoid Time Lost Looking for or Verifying Correct Items:

Color Coding

Number Coding

Proper Arrangement and Orderliness

Carts Reserved for Changeovers

Material Flow Racks

Go-No Go Gauges

Simplify Adjustments

Dedicated setup equipment and carts

Continuously Collect Ideas to Improve Setup!

Remember that all improvements begin and end with the Five S’s!