Reduce changeover time with SMED
Every minute a machine stands still for a product change costs capacity. With a structured SMED approach I bring changeover times down for good, so you can run smaller batches and plan more flexibly.
Does this sound familiar?
- Changeovers take a long time and differ per shift or operator.
- Several people are needed to carry out a single changeover.
- Planning favours large batches because changing over is “too expensive”.
- After a changeover it takes a long time before the line produces good product again.
- Your OEE lags behind, and availability is the biggest loss.
Results at Philips Drachten
On a production line for baby products, frequent product changes caused long downtime. With SMED we brought the changeover down:
This delivered higher machine availability, more planning flexibility and lower operational costs. Read the full case.
My SMED approach in five steps
- Record. Film the current changeover and time every action, together with the operators.
- Separate. Split actions into internal (machine must be stopped) and external (can be done during production).
- Convert. Turn as many internal actions as possible into external ones: preparing, staging, presetting.
- Streamline. Speed up the remaining steps: quick-release fixings, fixed references, less adjustment, working in parallel.
- Sustain. New standard work instructions, training on the floor and measuring whether the gains hold.
The difference is in sustaining the result. A fast changeover during a kaizen week is easy; hitting the same time on the night shift three months later is the real result.
Frequently asked questions about SMED
What is SMED?
SMED stands for Single Minute Exchange of Die: a Lean method to drastically shorten changeover times on machines and production lines. The aim is to change over in single-digit minutes, so under ten minutes.
How much changeover time can SMED save?
That depends on the starting point. Reductions of 50% are common; at Philips Drachten I achieved 80%: from 45 to 10 minutes per changeover.
How long does a SMED project take?
A first analysis and improvement round on a single machine or line usually takes a few weeks. The duration depends on the number of changeovers, their complexity and how quickly changes can be implemented.
Is SMED only suitable for large companies?
No. Especially with smaller batches and frequent product changes, SMED pays off quickly, because every minute gained translates directly into capacity and flexibility.
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