SMED Setup Time Reduction Worksheet
SMED, single minute exchange of die, is Shigeo Shingo's method for cutting changeover time by separating work done with the machine stopped from work done while it runs. This worksheet lets you list every changeover element, assign an improvement action and see the downtime you can remove.
| Changeover element | Today | Internal min today (min) | External min today (min) | Improvement action | Internal min target (min) | External min target (min) | Downtime saved | |
|---|---|---|---|---|---|---|---|---|
12 min | ||||||||
10 min | ||||||||
8 min | ||||||||
7 min | ||||||||
13 min | ||||||||
4 min |
Internal means the machine must be stopped. External means it can be done while the machine runs. Walk the changeover with a stopwatch or video, list every element, then challenge each internal element.
Get setup times into your ERP schedule
Optional: a quick review of how your ERP handles setup and sequence-dependent changeovers.
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How to use the worksheet
Record a real changeover on video or with a stopwatch and list each element as a row with its duration. Put the minutes in the internal column if the machine was stopped and in the external column if it was running. Choose an improvement action for each row, then enter the internal and external target minutes you expect after the change. The saved column and the summary show how much stopped time you remove per changeover. Export to Excel to attach to a kaizen event report.
- Include waiting, walking and searching, not only the hands-on work.
- Have the operators who do the changeover fill in the targets.
- Review the worksheet again after the first trial, because predictions are usually optimistic.
The SMED stages
Shingo described stages. Stage zero is observing the current state without separating anything. Stage one separates internal from external elements. Stage two converts internal elements to external ones, for example by pre-staging tools, material and programs. Stage three streamlines what remains, using quick-release clamps, fixed stops, standard heights, visual gauges and parallel operators. The worksheet columns follow this order: classify, convert, then streamline or eliminate. Adjustments and trial runs are usually the largest remaining block, so target them directly.
Reading the result
The headline number is the percent reduction in machine downtime per changeover. In the sample, internal time falls from 78 to 24 minutes, a reduction of about 69 percent. Multiply minutes saved by changeovers per week and your machine hourly rate to see the value. Shorter changeovers also let you run smaller lots, which cuts WIP and lead time, but only if the scheduler is allowed to change lot sizes and sequence to use the new capacity.
Common mistakes
Teams often start with expensive quick-change tooling before they have done the free work of converting internal elements to external ones. Another mistake is counting the saved minutes as capacity without checking whether the machine is the constraint. Savings on a non-bottleneck machine do not raise plant output. Finally, if the new standard work is not written down and audited, changeover times drift back within weeks.
Frequently Asked Questions
What counts as an internal element in SMED?
An internal element is any activity that can only be done while the machine is stopped, such as removing a die or clamping a new fixture. If the activity could be done while the machine is still running, it is external and should be moved out of the downtime window.
How much can SMED reduce changeover time?
Reductions of 50 percent are commonly achieved in the first round, mostly by moving preparation work outside the stoppage. Beyond that gains depend on tooling and machine design. Treat any specific target as a hypothesis to test in a trial changeover.
Does SMED only apply to presses and dies?
No. It applies to any machine or line with changeovers, including CNC mills, injection molding, SMT lines, packaging lines and mixers. The method is the same: observe, separate, convert, streamline. Only the typical improvement actions differ.
Should I put changeover times in the ERP?
Yes, if the ERP scheduler supports setup times, because it improves sequencing and promise dates. Use the post-SMED target as the standard once it is stable, not the best run ever observed. Keep an eye on actual versus standard.
If changeover times and sequence-dependent setups should drive your ERP schedule, Netray can help map them into SyteLine, SAP, Epicor or your MES so the scheduler uses real numbers.
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