SMED — QUICK CHANGEOVER TOOLKIT

Every minute a line stands idle between one product and the next is pure waste — and long changeovers quietly force big batches, extra stock and slow response to customers. SMED (Single-Minute Exchange of Dies) is the disciplined way to cut that idle time down to single digits. This complete Module 6 toolkit teaches the method and hands you a ready-to-use form to run a real changeover study the same day.

Ideal for production and maintenance teams, team leaders, and continuous-improvement people on any line, cell or machine — no prior Lean background needed.

WHAT YOU GET

- Training slides (PPTX): a 23-slide deck across three sections — what SMED is (origins & benefits), the six-step process, and how to optimize & sustain.

- Reference guide (DOCX): a concise pocket guide to the method, internal vs. external setup, and the ECRS questions — keep it by the machine.

- Changeover observation form (XLSX): record, time and classify every step, then plan the improvement — with a full worked changeover example.

THE CORE IDEA: INTERNAL VS. EXTERNAL

Every changeover step is either internal (only possible with the machine STOPPED) or external (safe to do while it RUNS). The whole game is to move as much work as possible off the stopped machine, then streamline what's left — so the line is down for the shortest time possible.

THE SIX-STEP PROCESS

1 - Identify: observe and record every changeover step.

2 - Measure: time each step and the total changeover.

3 - Classify: split every step into internal or external.

4 - Convert: turn internal steps into external ones.

5 - Optimize: streamline what's left with ECRS (Eliminate, Combine, Rearrange, Simplify).

6 - Standardize: train the new method and hold the standard.

Steps 1-3 understand the changeover; steps 4-6 improve it and make the gains stick.

WHY IT PAYS OFF

- Shorter lead time: smaller batches mean less stock, handling, floor space and cost.

- Less downtime: fewer changeover losses lift OEE and free up capacity.

- More flexibility: switch products easily and schedule closer to real demand.

- Easier training: simple, standard setups make operators quick to train.

- Fully editable: record, time and classify any changeover in Excel.

- A proven method: the same approach that took Toyota from four hours to three minutes.

WHAT'S IN THE DOWNLOAD

- 1 x Training deck — .pptx (23 slides, fully editable)

- 1 x Reference guide — .docx (pocket guide, editable)

- 1 x Changeover observation form — .xlsx (observation form + worked example)

Instant digital download. For personal and in-company training use.