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Lean SMED system for change over setup reduction
Your lean objective
is throughput, not output
(Inventory that is sold,
not just produced)
Maximize lean flow
(happening during the normal process run cycle)
to 'external setup time'
(happening before or after the normal process run cycle)
Setup reduction is important because Flow requires small batches.
And flow enables everything else that you're trying to accomplish with lean.
If your executive leaders are not already enthusiastic active champions for lean flow, then before you get into the weeds of 'how' to achieve flow, everyone on your team needs to first understand 'why' flow is so important
1) Flow enables Pull
2) Flow Improves Safety
3) Flow Improves Quality
4) Flow Improves Speed of Delivery
5) Lean Flow Improves Cash Flow
6) Flow Improves Productivity
7) Flow Improves Clarity
8) Flow Improves Morale
9) Flow Enables Offense
Learn more about lean flow
Before you start
Launch your team, using the same tools and systems that you use to launch any team.
Analyze the Current State of your 'As Is' Process
Follow the instructions for how to use your Standard Work template to:
1) Enter your Time Observations
2) Perform Standard Work Analysis of your current state
3) Generate your Standard Work Combination Sheet
If you haven't used a Standard Work Combination Sheet in a while, you will definitely want to refresh your memory for that training section, because the definitions of an 'External Step' and an 'External Operator ' are absolutely essential for SMED Setup Reduction.
Watch this video
Standard Work Video 6:
Run Cycle Analysis, and
Standard Work Combination Sheet
Copy your 'As Is' workbook to create your 'To Be' workbook
Your Standard Work Template is designed to have only one 'StdWk' sheet, so rather than making a second sheet in the same workbook, you should copy the entire workbook.
Rename the copied workbook, using suggested document naming conventions, and save the copied workbook in the same folder with the original — to avoid breaking links to related documents.
Now you're ready to start using your template for
Redesign your work flow —
looking for opportunities to:
by using jigs, guides, and mistake-proofing and time-saving devices and methods for your unique process
to stimulate Lean Thinking
Look for any row that has a 'Frequency' other than 'Run'
(or blank which is the same as 'Run')
Can anyone come up with any creative ideas for how to reduce those activities?
by rearranging tasks to allow operators to do something productive instead of just waiting for a machine to finish
Plug in 'what if' numbers.
What is currently the smallest 'Batch Size' before 'Capacity' becomes lower than 'Demand'?
Remember, however, that the (one) Pacemaker process in a value stream usually determines the batch size for all other upstream and downstream processes in the value stream.
So if the process that you are analyzing happens to be the Pacemaker process, then you should use both this Standard Work template and your Value Stream Mapping template to calculate the Optimum Changeover Batch Size for the entire value stream.
a) Look for steps that might happen less frequently.
Change the 'Frequency' code.
Perhaps once per Batch. Or twice per Shift. Etc.
b) Look for steps that might be performed by an External Operator.
In the 'Op' column, enter 'minus 1' (-1), which will then display as Operator 'X' (for eXternal)
Then use Shift Down and Move to move entire rows
The chart requires all 'Run Cycle' steps to be grouped together for each Operator.
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That might require you to move some steps to appear before or after the Run Cycle steps for that operator.
(Even if the steps might actually happen during the middle of that operator's Run Cycle steps, you need to keep all Run Cycle Steps together for each Operator.)
Make your plans real
Just envisioning a good idea doesn't make it so.
Use your lean management systems to make your plans real.
A doctor's office visit might take a lot longer if your health care provider wasted time changing out bedsheets and restocking supplies after you arrived — rather than arranging for those things to be done before you ever walk into the exam room.
Sample Quick Changeover example.
This animation shows the older version of this template. Download free trial to play with the latest.
This example also illustrates why we prefer to call it "quick changeover" or "setup reduction".
Would you want to go to a doctor that specializes in "single minute exchange of dies"? (SMED)
The other template that is extremely helpful for Quick Changeover Setup Reduction is your value stream mapping template.
One of the many powerful things that your Systems2win value stream mapping template can do for you is to automatically calculate your optimum Change Over Batch Sizes.
Set up reduction is needed for every industry.
It is often even more important in Lean Administration and Lean Healthcare than it is in Lean Manufacturing because it is so rare for anyone in an office environment to do anything for an entire shift.
White collar workers are constantly switching between batches of different types of work.
Improve ANY process
in ANY industry
Examples of office change-overs might include:
And office change-over time can also be hidden within more subtle tasks, like:
Just ask any "thinking" worker about how frequent interruptions
affect their quality and productivity
The templates that you will use for
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