Quick Changeover (SMED)

Quick Changeover Workshop Overview

Quick Changeover is a method for rapidly and efficiently converting a process from running the current product to running the next product. Quick Changeover can, and often is, used in starting up a process and rapidly getting it to running condition with minimum waste. Quick Changeover is a concept that says all changeovers (and startups) can and should take less than 10 minutes. Closely associated is an advanced concept of OTED (One-Touch Exchange of Die), which says changeovers can and should take less than 100 seconds. We have worked with a number of companies who have reduced their setups and changeovers from several hours to 30 minutes or less on the first try.

Learning Objectives

Quick Changeover can be applied to critical processes to reduce batch sizes, reduce work-in-process inventories, achieve shorter lead times, and thereby reduce product costs (bottom line $) and increase flexibility to meet changing customer demands.

Program Agenda

Quick Changeover Workshop - 3 Days

The workshop consists of learning the Quick Changeover concept via a presentation and an active simulation, then applying the 16-step Quick Changeover method to your own processes. A key part of this is properly defining setups and changeovers as the time elapsed between the last unit of good product on your current run to the first unit of good product on your next run.

Quick Changeover - Day One

• Introduction and getting started


• The 16-step SMED / Quick Changeover Process


• Quick Changeover Simulation (Changing a Car Tire)


• Analyzing your current Changeover Process


• Videotaping your current Changeover Process

Quick Changeover - Day Two and Three

• Applying the 16-step SMED / Quick Changeover Process to your Value Stream


• Creating your new SMED / Quick Changeover Process


• Getting a baseline for SMED / Quick Changeover in your Value Stream


• SMED / Quick Changeover Checklist


• SMED / Quick Changeover Radar Chart

Summary – at the end of Day Three

• Measuring the business impact of SMED / Quick Changeover in your Value Stream


• Quantifying the changes required to incorporate the new SMED / Quick Changeover Process


• Create specific / detailed Kaizens


• Formalize and present out to senior management for plan acceptance


• Workshop conclusion

Who Should Attend?

The Quick Changeover workshop is for those individuals whose task is to design, lead, and
work in a Value Stream.
These could be:

• Operational Leaders


• Value Stream Managers


• Operations Associates


• Maintenance Personnel


• Engineers


• Quality


• Trainers

Prerequisites

Novices to KAIZEN Lean implementation should attend 'Introduction To KAIZEN Lean' first to familiarize themselves with the basic concepts and principles of KAIZEN Lean. We also recommend Enterprise Value Stream Mapping before Quick Changeover so you’ll know where to apply this important KAIZEN Lean tool and what results are required to meet the customer demand.