SMED Express

SMED

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SMED Express: Accelerating Changeover Reduction for Operational Agility

The SMED Express concept represents a focused, accelerated application of the foundational Lean manufacturing methodology known as Single-Minute Exchange of Die (SMED). Developed by Shigeo Shingo, SMED is a systematic approach aimed at drastically reducing the time required to complete equipment changeovers or setups, ideally to a “single-minute” digit (less than 10 minutes) . The “Express” designation signifies a rapid, often Kaizen-style, implementation of the core SMED principles, designed to deliver measurable results in a matter of days or a single week.

The Strategic Importance of Quick Changeover

In modern manufacturing and service environments, long changeover times are a major source of waste (Muda). They force companies to run large production batches to maintain efficiency, which in turn leads to high inventory levels, increased lead times, and reduced flexibility to meet fluctuating customer demand. By implementing SMED Express, organizations can achieve operational agility, enabling them to produce smaller batches economically and respond quickly to market changes.

The Four-Step SMED Methodology

The SMED Express process follows the four fundamental stages of the original SMED methodology, but with an emphasis on speed and immediate action:

1. Separate Internal from External Setup

The first step involves a detailed observation and analysis of the current changeover process, typically through video recording. The team then categorizes every step into one of two types:

•Internal Setup (IDE): Operations that must be performed while the machine or process is stopped (e.g., removing a die, making final adjustments).

•External Setup (EDE): Operations that can be performed while the machine or process is running (e.g., fetching tools, preparing the next die, cleaning the area).

The goal of this stage is to maximize the number of external steps, thereby minimizing downtime.

2. Convert Internal to External Setup

This is the most critical step. The team brainstorms and implements solutions to convert as many internal steps as possible into external ones. Common conversion techniques include:

•Pre-staging: Ensuring all necessary tools, parts, and materials are organized and brought to the machine before the machine stops.

•Pre-assembly: Assembling components of the new setup offline while the previous job is running.

•Functional Checks: Performing quality and functional checks on the new setup before installation.

3. Streamline All Setup Elements

Once the separation and conversion are complete, the team focuses on simplifying and accelerating the remaining internal and external steps. This involves eliminating waste within the setup itself. Key techniques include:

•Eliminating Adjustments: Replacing time-consuming adjustments (e.g., tightening multiple bolts) with standardized, pre-set mechanisms.

•Using Quick-Fasteners: Replacing bolts and nuts with quick-release clamps, cam locks, or bayonet fittings.

•Standardizing Tools: Reducing the number of tools required and ensuring they are immediately accessible.

•Parallel Operations: Designing the process so that multiple operators can work simultaneously and safely.

4. Standardize the New Procedure

The final step ensures the gains are sustained. The team documents the new, optimized changeover procedure as the Standard Work. This includes visual aids, checklists, and clear roles and responsibilities. Training is conducted immediately to ensure all operators adhere to the new, faster method. This standardization prevents backsliding and provides a baseline for future continuous improvement efforts.

Key Benefits of SMED Express

By focusing on rapid implementation, SMED Express delivers immediate and tangible benefits:

1.Increased Capacity: Reduced downtime means more available machine time, increasing overall production capacity without capital investment.

2.Improved Flexibility: The ability to perform quick changeovers allows for smaller batch sizes, enabling a faster response to customer orders and reduced finished goods inventory.

3.Reduced Inventory: Smaller batches reduce the need for large safety stocks of raw materials, work-in-progress (WIP), and finished goods.

4.Enhanced Quality: Less time spent on changeover means less opportunity for errors, and the standardization process inherently improves the consistency of the setup.

Smed Data Sheet

No.	Activity	INT / EXT
1	Machine stop (last good part)	INT
2	Disconnecting and removing tooling	INT
3	Storing / cleaning removed tooling	EXT
4	Transport and preparation of new tooling	EXT
5	Mounting and connecting tooling to the machine	INT
6	Adjustment and fine tuning	INT
7	Tool / machine preheating	INT/EXT
8	Machine start-up	INT
9	First good part produced	INT
	TOTAL Internal Time (min)
	TOTAL External Time (min)
	TOTAL Changeover Time (min)

SMED Express

SMED

SMED Express: Accelerating Changeover Reduction for Operational Agility

The Strategic Importance of Quick Changeover

The Four-Step SMED Methodology

Key Benefits of SMED Express

Smed Data Sheet

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