Guide

SMED Guide: Reducing setup times

Learn more about discrete manufacturing consulting

SMED (Single Minute Exchange of Die) is a structured methodology focused on systematically reducing reference changeover times, with a direct impact on flexibility and operational efficiency. This methodology is characterized by:

• Significantly reducing setup time
• Increasing operational flexibility
• Improving process flow
• Enabling small batch production
• Increasing available capacity without the need for additional investment in equipment

SMED is currently one of the most effective methodologies for organizations seeking to increase agility, competitiveness, and operational robustness, and can be applied to any industry or activity.

The 5 steps of SMED

The implementation of SMED evolves from an unstructured setup to a fast and standardized process that follows these steps:

0. Unoptimized setup work
Initial situation with waste and lack of standardization.

1. Study the work
Detailed analysis of the setup to identify opportunities for improvement.

2. Separate internal and external work
Differentiation between tasks performed with the machine stopped and in operation.

3. Convert internal work into external work
Transformation of internal activities into external ones to reduce downtime.

4. Reduce internal work
Simplification and optimization of critical tasks to be performed with the machine stopped.

5. Reduce external work
Organization and standardization of preparatory activities.

The conditions for SMED sustainability

For the SMED implementation to produce consistent results over time, it is essential to ensure discipline in execution and continuous monitoring of the new standards. Consolidating improvements requires adequate training, a clear definition of responsibilities, and audit mechanisms that ensure compliance with the defined methods. Without these additional components, the gains obtained tend to be diluted and the process gradually returns to its initial state.