SMED in brief

  • No set-up should take more than 9 minutes
  • It is a systematic approach that decreases disturbances and problem
  • Based on team-work and creativity
  • SMED methods is used for exchange of dies, but also for cleaning, and for regular maintenance

Change over time is defined as the time difference of the last product produced and the next new product produced with the right quality and at the right speed.

Why decrease set-up times? 

Production sites with long set-up times are characterized by

  • Low flexibility
  • Large batch sizes
  • High level of stocks

If we decrease the set-up times we could use the extra capacity either to increase productivity or to decrease the batch sizes. Typical benefits are:

  • Reduction in lead time and hence improved and faster delivery
  • Higher productivity
  • Reduction in working capital
  • Makes Kanban – systems possibly
  • Less disturbances

SMED Implementation

So how could SMED be effectively implemented?

Based on my experience, the following steps are the key treads that would best guarantee the successful implementation:

Step 1 Focus. Start by choosing the right equipment to start with. This is normally a bottle-neck with long set-up times

Step 2 Build the right team. Work cross-functional. Operators, Technicians, Engineers and Managers should work together

Step 3 – Measure and set goals. Visualize the present situation and agree on a common goal

Step 4 – 5S. To succeed you will need a clean and well organized work-place. A 5S implementation is recommended

Step 5 - Analysis. Keenly observe the operations and processes. Analyze the present situation video-technique. The different moments are classified as being external or internal and waste or not waste. All known disturbances are listed as well.

"SMED Video analysis "

Step 6 – Separation between internal and external moments. The purpose is to secure that all external set-ups are performed when the machine is running. Use checklists, function controls and improved transports. For example collect necessary tools and consumables before the next operation starts up or sharp the tools before activity starts.

Step 7 - Elimination of waste. Measures are carried out to reduce all types of waste. This includes:

  • Elimination of all need for adjustments.
  • Exchange of bolts for quick-fasteners.
  • Standardized parts, tools, dimensions
  • Increased number of equipments
  • Improved team-work.
  • Need for quality control

Step 8 Follow up and improve. Make sure that your new level sets the new standard

How to start

Many use consultants for training in the SMED method. If you prefer a do-it-yourself alternative please consider our PowerPoint presentation complete with trainers manual and workshops. Follow this link for a free demo

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