LEAN Toolboxby Availix · Interactive LEAN tools

Purpose and method

Analyze changeover activities and reduce internal setup time by converting and improving work steps.

When to use it

Use SMED when product changeovers reduce availability, force large batches or create unstable start-up conditions.

Core principle

SMED reduces the time between the last good piece of the previous run and the first good piece of the next run. It first separates work that truly requires a stopped machine.

What the interactive module provides

  • Timed changeover record
  • Internal/external activity analysis
  • Improved parallel work plan
  • changeover timeline, classified activities, improvement ideas, parallel plan and new standard
Professional verification: The module supports learning, analysis and documentation. Verify results against actual process conditions, internal standards, safety requirements and competent professional judgement before implementation.
01

Recommended workflow

Record changeover activities, classify internal and external work, expose parallel opportunities and build a safer reduced-time standard.

  1. 1

    Define exact start and first-good-piece end points

  2. 2

    Record every activity and waiting period

  3. 3

    Separate internal and external work

  4. 4

    Convert, simplify and safely parallelise activities

  5. 5

    Trial the method and publish standard work

02

Practical example

A 74-minute die change includes 21 minutes of searching and preparation after shutdown. Moving preparation external and running two safe tasks in parallel reduces downtime to 39 minutes.

Calculation or verification principle

Changeover reduction = baseline time − improved time. Report both total elapsed time and machine-stopped internal time; do not hide quality approval after restart.

Required inputs → Expected outputs

Required inputs
video or observations, activity sequence, duration, role, internal/external status, dependencies and safety constraints
Expected outputs
changeover timeline, classified activities, improvement ideas, parallel plan and new standard
03

Common mistakes to avoid

×

Measuring only mechanical work and omitting approval

×

Classifying work without observing the stopped condition

×

Parallelising tasks that create interference or risk

×

Reducing time by transferring burden to another shift

04

Frequently asked questions

What data do I need to use this tool?

Prepare video or observations, activity sequence, duration, role, internal/external status, dependencies and safety constraints.

What result does the module produce?

The module produces changeover timeline, classified activities, improvement ideas, parallel plan and new standard.

Can I implement the result without further review?

No. Treat the output as a structured engineering and improvement aid. Verify source data, assumptions, safety, quality, legal requirements and local process conditions with competent responsible people before implementation.

05

Related LEAN tools

Standard WorkDefine the safest current best-known sequence, expected timing, standard inventory and key quality points so work can be trained, observed and improved.5S Workplace OrganisationBuild a visual workplace standard, evaluate every 5S step and turn findings into a practical action plan.OEE – Overall Equipment EffectivenessCalculate Availability, Performance and Quality from transparent production data and trace the OEE gap to concrete loss categories.Total Productive Maintenance (TPM)Structure equipment losses, operator care, inspection standards, planned maintenance and improvement actions around the conditions required for reliable production.
LEAN Toolbox

SMED Changeover Analysis
Record changeover activities, classify internal and external work, expose parallel opportunities and build a safer reduced-time standard.

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