SMED Changeover Analysis Worksheet (Excel Export)

The method behind it

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.

• 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

Common mistakes

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.

• 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

Frequently Asked Questions