Continuous operational improvements are the heart of lean manufacturing. In light of that, it is not difficult to understand why Lean manufacturing has continued to be a core framework for reducing waste, increasing responsiveness, and improving productivity across operations. In the spirit of Lean, an effective way to make improvements on the plant floor is by optimizing changeovers—to decrease downtime and increase efficiency.
In many instances, changeovers are long, inconsistent, or poorly managed. They can create significant downtime, increase labor costs, and introduce quality risks.
So, how can manufacturers streamline changeovers? Introducing SMED, or Single-Minute Exchange of Die. When implemented thoughtfully and supported by a Manufacturing Execution System (MES) platform, such as TrakSYS, SMED can empower manufacturers to embrace Lean methodologies, respond faster to demand, and operate with greater flexibility.
Table of Contents
What is SMED?
A term originating from the automotive industry, where die changes in stamping presses could take hours, SMED (Single-Minute Exchange of Die) is a lean methodology focused on reducing equipment changeover times—potentially to as low as under 10 minutes.
However. Not every industry or process can achieve a literal “under 10 minutes” changeover. For example, in highly regulated sectors, such as food and beverage or pharmaceuticals, stringent safety and quality protocols may prevent sub-10-minute targets. But the core philosophy of SMED still applies: systematically reduce changeover time by identifying and converting internal tasks to external ones wherever possible.
The Three-Step SMED Implementation Process
Implementing SMED isn’t just about working faster—it’s about working smarter. The SMED methodology offers a structured approach for rethinking how changeovers are performed.
Before getting started, it’s crucial to understand what internal and external “elements” mean in this methodology:
Internal Elements: changeover tasks that must be completed while the equipment is stopped
External Elements: changeover tasks that can be completed while the equipment is running
With those definitions out of the way, let’s take a look at the three key steps of an effective SMED initiative:
- Separate: Break down your changeover into individual tasks and distinguish them as either internal or external.
- Convert: Transition as many internal tasks as possible to external tasks—like pre-staging tools or prepping materials while equipment is still operating.
- Streamline: Optimize remaining internal activities. Use standardization, automation, and parallel work to minimize delays and variation.
Successfully implementing SMED begins with a strong operational foundation—one that’s grounded in accurate, timely data. Before improvements can begin, manufacturers should ensure they have a system in place to collect manufacturing performance data. Ideally, this includes the routine tracking of changeover times and Overall Equipment Effectiveness (OEE) metrics, which provide a holistic view of how equipment is performing in terms of availability, performance, and quality.
Establishing a baseline is essential to effectively measure the progress of a SMED program. By gathering past data on past changeover times, teams can begin to identify inefficiencies, prioritize high-impact areas, and set realistic targets for improvement. Without this initial baseline visibility, it’s nearly impossible to understand where during the changeover time is being lost and how much of it can be recovered through SMED.
Once data collection is in place, you’re ready to begin the SMED process. At this stage, cross-functional collaboration becomes critical. Involving operators, engineers, and line supervisors ensures that improvement efforts have the necessary buy-in to succeed. As SMED improvements take shape, these stakeholders can help sustain momentum and ensure new procedures are followed consistently.
This data-driven, collaborative approach sets the stage for lasting change, allowing manufacturers to systematically reduce changeover time, increase responsiveness, and strengthen their overall lean manufacturing strategy.
Practical Examples of SMED
So, what does the breakdown and conversion of SMED elements look like in practice? Here are some common examples you can envision on the plant floor:
Converting Internal to External
- Pre-stage tools and materials
- Use duplicate jigs or fixtures that can be set up offline
- Modularize machine components for faster swaps
- Prepare mobile setup carts with all necessary items
Streamlining Internal Activities
- Replace bolts and screws with quick-release mechanisms
- Eliminate on-the-fly adjustments through pre-calibration
- Use color-coded visual aids for positioning
- Enable parallel operations where possible
Key Benefits of SMED
When properly implemented, SMED brings a wide range of benefits—beyond faster changeovers—that can impact nearly every aspect of plant performance, including:
Improved Agility
Implementing SMED practices can enhance production flexibility, allowing manufacturers to shift between different products or batches with minimal delay. This agility makes it possible to respond more quickly to shifting customer demands or shorter product lifecycles, which is critical in today’s dynamic market conditions. With faster and more consistent changeovers, it becomes practical to run smaller batch sizes without sacrificing productivity.
Standardization
By establishing consistent changeover procedures, manufacturers reduce variability and increase repeatability, thereby improving product quality. When every team member consistently follows the same steps, the likelihood of mistakes, especially during complex tasks, is significantly reduced.
Better Equipment Utilization
SMED improves equipment utilization by ensuring that production assets are engaged more consistently. This means higher throughput from the same resources and better return on capital investments.
Ultimately, SMED empowers teams to work smarter, so they can have more time and resources to allocate elsewhere, thus transforming changeovers from a bottleneck into a competitive advantage.
Common Deployment Challenges
While the benefits of SMED are compelling, implementing it is not without challenge. That said, obstacles often arise during the early stages of deployment and can be mitigated with thoughtful planning, the right tools, and a commitment to continuous improvement.
Here are some common obstacles and how to address them:
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Challenge
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Solution
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Team members resistant to change
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Involve operators early; celebrate quick wins
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Lack of standardization
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Implement digital work instructions
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Poor data quality
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Deploy real-time monitoring and MES tools
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Sustaining improvements
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Integrate SMED metrics into daily management
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Measuring Success
The success of a SMED initiative is best gauged by a combination of performance metrics that collectively reflect speed, consistency, and quality:
Average Changeover Time
The most straightforward metric is average changeover time, which provides a baseline for how long it takes to complete a typical change from one product or setup to another. Reductions in this metric are a clear indicator that improvements are taking hold.
Changeover Time Variability
Tracking the variation in changeover times helps identify whether procedures are reliably followed or if outcomes are still unpredictable. Wide variation often signals gaps in standardization, training, or process clarity—all areas that SMED seeks to address.
First-Pass Quality Post-Changeover
If product defects or rework rates spike immediately after equipment is switched over, it may indicate problems with calibration, operator understanding, or equipment readiness. A successful SMED deployment should stabilize or improve quality immediately following setup.
Equipment Availability Improvements
This is a key component of OEE, demonstrating how SMED contributes to broader operational efficiency. When changeovers take less time and occur with fewer issues, machines spend more time producing, which improves overall throughput.
Tracking these indicators over time enables teams to assess SMED progress and prioritize further improvements.
Using an MES to Improve SMED
An MES like TrakSYS can accelerate SMED implementation by digitizing key elements of the changeover process:
Automated Data Collection
Enable real-time tracking of changeover activities for detailed analysis.
Digital Work Instructions
Make standardized procedures accessible via tablets or HMIs with step-by-step visuals.
Performance Dashboards
Identify real-time changeover trends and anomalies.
Continuous Improvement Tools
Utilize root-cause analysis, Pareto charts, and benchmarking to support lean initiatives.
Conclusion
SMED is more than a lean manufacturing technique—it’s a practical approach to unlocking operational efficiency. No matter your industry, reducing changeover time can drive measurable impact across your manufacturing operations.
When supported by an MES like TrakSYS, SMED can deliver both immediate efficiency and long-term sustainability. It enables standardized practices, empowers operators, and enhances visibility—all through understanding and optimizing changeover processes.
If you’re looking to implement or optimize SMED as part of your lean strategy, contact us today to learn how TrakSYS can help streamline changeovers and elevate overall performance.
FAQ
What is the goal of SMED?
Can SMED be applied in highly regulated industries?
How does SMED support broader lean initiatives?
What role does MES software play in SMED?
MES platforms like TrakSYS automate data collection, digitalize work instructions, and provide real-time performance insights. These capabilities make SMED easier to implement, monitor, and sustain.