SMED Changeover Element Analysis Worksheet
A SMED project starts with watching one real changeover and writing down every element. This worksheet gives you the table: step, element, internal or external, current time, an improvement idea, planned time and the minutes saved, with totals that update as you edit.
| Step | Element observed | Type | Current time (min) | Improvement idea | Planned time (min) | Saved (min) | |
|---|---|---|---|---|---|---|---|
6 min | |||||||
10 min | |||||||
6 min | |||||||
6 min | |||||||
12 min | |||||||
12 min |
Record a real changeover on video or with a stopwatch before filling in the Current time column. Tag every element as Internal (machine stopped), External (can be done while running) or Waste (searching, waiting, rework). Move External work outside first, then shorten Internal work.
Keep ERP routing setup times honest
Optional: we can look at how to compare planned and actual setup times from your system.
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How to use the worksheet
Film a changeover from the last good part to the first good part. Replay it with the team and list each element in order, noting its duration. Tag it Internal if the machine must be stopped, External if it could happen while the machine runs, or Waste for searching and waiting. Then add improvement ideas and a planned time for each. The worksheet totals current and planned minutes and shows the percentage reduction. Export to Excel to share the plan or attach it to an A3.
- Observe at the machine, with the operators, not in a meeting
- Time every element, including walking and waiting
- Add one row per action, not per phase
The SMED stages
Shingo described stages. Stage zero is observing, where internal and external elements are mixed. Stage one separates them. Stage two converts internal elements to external, for example presetting tools offline. Stage three streamlines both, using quick clamps, parallel operations and eliminating adjustments. Fill the idea column in that order: organize and stage first because it costs little, then convert, then redesign hardware. The Type column lets you filter and sort to see which stage each element belongs to.
Reading the example
The sample rows total 90 minutes today and 38 planned, a saving of 52 minutes or 58 percent. Notice where the savings come from: fetching tools and the missing wrench are pure organization, and the first article wait is a scheduling fix. Only the trial piece and offsets need engineering. This is typical: the first half of a SMED project is discipline, not equipment. Take the total reduction into the SMED savings calculator to price the hours released.
Common mistakes
Skipping the video and relying on memory produces a tidy list that misses the waiting and walking. Setting planned times without owner and date means ideas are never done. Changeover standards also need to be checked after a month, since people drift back. Finally, do not forget elements that happen after the first part, such as adjustments and approvals, because the machine is still not making sellable product until they finish.
- Record on video and review as a team
- Give each idea an owner and a date outside this sheet
- Re-time the changeover after 30 days
Frequently Asked Questions
What is an internal versus external element?
Internal work can only be done with the machine stopped, such as removing a die. External work can be done while the machine is still running, such as fetching tools, preheating or staging the next material.
How many elements should a changeover have?
Between 15 and 40 for a typical machine tool or press. If you only have five rows you are summarizing, not observing, and you will miss the small wastes where much of the time hides.
Where do I record the target time?
In the Planned time column for each element. The worksheet totals them, so you can see whether the plan reaches your target changeover time before committing to changes.
Can I use this for non-machine changeovers?
Yes. The same split applies to line clearances in packaging, mold changes, batch process cleaning and even office processes. Rename the columns as needed in Excel after export.
If your ERP routing carries setup times that no longer match reality, we can help compare planned and actual setup durations and keep routings honest.
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