# SMED Changeover Analysis Worksheet (Excel Export) > Source: https://netray.co/tools/smed-changeover-analysis-worksheet > Publisher: Netray (netray.co), AI and integration engineering for ERP and manufacturing systems. > Section: Free Tools ## Short answer Break a changeover into steps, mark what can move outside machine stoppage, and total the minutes you recover. ## Category mes-shop-floor ## Industry Discrete Manufacturing ## Audience - Continuous improvement manager - Plant manager - Production supervisor ## Tool **Kind:** worksheet **Mode:** editable **Columns:** #### Changeover step **Key:** step **Type:** text #### Today **Key:** class **Type:** select **Options:** - Internal - External #### Who **Key:** owner **Type:** text #### Minutes today **Key:** minutes **Type:** number **Format:** minutes #### Minutes moved outside stoppage **Key:** externalize **Type:** number **Format:** minutes #### Minutes cut by simplifying **Key:** reduce **Type:** number **Format:** minutes #### Machine-stopped minutes after **Key:** after **Type:** number **Format:** minutes **Expr:** max(minutes - externalize - reduce, 0) **Rows:** #### Fetch next die and fixtures from rack **Class:** Internal **Owner:** Operator **Minutes:** 12 **Externalize:** 12 **Reduce:** 0 #### Unbolt and remove old die **Class:** Internal **Owner:** Operator + setter **Minutes:** 18 **Externalize:** 0 **Reduce:** 8 #### Position and clamp new die **Class:** Internal **Owner:** Setter **Minutes:** 22 **Externalize:** 0 **Reduce:** 10 #### Preheat die and verify tooling temperature **Class:** Internal **Owner:** Operator **Minutes:** 15 **Externalize:** 15 **Reduce:** 0 #### Load new program and offsets **Class:** Internal **Owner:** Setter **Minutes:** 9 **Externalize:** 5 **Reduce:** 2 #### First piece approval and adjustment **Class:** Internal **Owner:** Quality + setter **Minutes:** 25 **Externalize:** 0 **Reduce:** 8 **Totals:** #### Total minutes today **Key:** minutes **Agg:** sum **Format:** minutes #### Stopped minutes after **Key:** after **Agg:** sum **Format:** minutes **Summary:** #### Minutes saved per changeover **Key:** saved **Expr:** sum_minutes - sum_after **Format:** minutes **Primary:** true #### Reduction **Key:** pct **Expr:** if(gt(sum_minutes,0), (sum_minutes - sum_after) / sum_minutes * 100, 0) **Format:** percent **Notes:** Time a real changeover on video first, then fill the table from the recording. Internal means the machine must be stopped, external means it can be done while the previous job runs. Moved-outside minutes leave the stoppage entirely; cut minutes are steps you shorten with quick-release clamps, standard heights or pre-set tooling. ## Content **Intro:** SMED (single-minute exchange of die) is the standard method for shortening changeovers, and the first step is always a written analysis of what happens during the stoppage. This worksheet lets you list each step, mark it internal or external, and estimate the minutes you can recover. **Sections:** #### How to use the worksheet **Body:** Film one complete changeover from last good piece of the old job to first good piece of the new job. Replay the video with the operators and write every step as a row, including walking, searching and waiting. For each row enter the minutes it takes today, then decide how many of those minutes could happen while the machine is still running, and how many you can remove by redesign. The last column calculates the minutes the machine is still stopped, and the summary shows the saving per changeover. #### The method behind it **Body:** SMED comes from the Toyota production system work of Shigeo Shingo. The method runs in stages: observe and record, separate internal from external elements, convert internal elements to external where possible, then streamline what remains with standard parts, quick fasteners and parallel work. Most plants find the biggest first gain in stage two and three, because fetching tools, preheating and paperwork were done while the machine sat idle only out of habit. **Bullets:** - Internal element: requires the machine to be stopped - External element: can be completed while the machine runs - Convert: preheat, pre-stage, pre-set, pre-load programs - Streamline: eliminate adjustments, use quick release, work in parallel #### Reading the result **Body:** The reduction percent tells you how far one round of improvement could take you. With the example data the stoppage falls from 101 minutes to 41. Multiply the saved minutes by the number of changeovers per week and your planned run rate to see the capacity you free up, then smaller lot sizes become realistic. Repeat the exercise after the changes are in place, because the second pass usually finds a further layer of waste that the first pass hid. #### Common mistakes **Body:** Teams often time the changeover from memory instead of from a recording, which hides waiting and walking. Others stop at the first pass and never standardize the new sequence, so the gain disappears within weeks. Define the endpoint as first good piece, not first piece, otherwise adjustment time is excluded from the number. Also record who does each step, because idle operators during an internal step are a clear sign of work that could be split. **Bullets:** - Start and end at last good piece and first good piece - Write the improved sequence as a standard work sheet - Check that moved-outside work really happens before the stop **Cta:** If changeover durations and job sequences already live in your ERP or MES, we can pull them into this view automatically so you can see which setups cost the most each week. **Faq:** #### What is a good target for changeover reduction? **Answer:** Many plants aim to cut stopped time by half in the first improvement cycle, mostly by converting internal work to external work. The original SMED goal of under ten minutes is a direction, not a rule, and depends on the machine and product. #### Should I include cleaning and first piece approval? **Answer:** Yes. The changeover runs from the last good piece of the old job to the first good piece of the new one. Cleaning, adjustments and approval all keep the machine from producing, so they belong in the worksheet and often offer the largest savings. #### Can I export the worksheet to Excel? **Answer:** Yes. Edit the rows in the browser, then export to Excel, PDF or CSV. Everything runs in your browser, so nothing is uploaded and no sign-up is needed. #### How does this connect to OEE? **Answer:** Changeover time is planned stop or setup loss, depending on your OEE convention. Shorter changeovers raise availability and make smaller batches economical, which also lowers inventory. Decide once whether changeovers count as a loss and keep that rule constant. ## Search terms smed worksheet, changeover analysis template, smed excel template, changeover reduction worksheet, internal external setup elements, setup time reduction form, quick changeover analysis --- Talk to an engineer: https://netray.co/contact?intent=erp_ai | Machine catalog: https://netray.co/agent/catalog.json