Free Quick Changeover / SMED Overview Training Video

By Ron Pereira Updated on May 17th, 2017

We continue to add new content over at Gemba Academy.  So far we’ve covered the following topics:

  • 5S Workplace Productivity. They say, “If you can’t do 5S, you can forget the rest.” Learn why 5S is far more than a housekeeping initiative as we teach you step by step how to implement and sustain 5S. This course is also available with Spanish Subtitles.
  • Dealing with the 7 Deadly Wastes. You may already know what the 7 deadly wastes are… but do you know how to defeat them? We’ll show you how as we take our cameras inside Ram Technologies, a custom foam fabricator located in Mukilteo, Washington. This course is also available with Spanish Subtitles.
  • Transforming Your Value Streams. Learn how to transform your value streams using lean tools and principles such as value stream mapping, takt time, kanban, error proofing, and heijunka/production leveling.

And most recently we’ve been hard at work on a course focused on Quick Changeover and SMED where subscribers of Gemba Academy have been learning how to radically reduce machine changeovers using the SMED (Single Minute Exchange of Dies) system while witnessing an actual changeover reduction kaizen unfold in front of their eyes.

Below is part 1 of this courses overview module. To see part 2 of the overview module, as well as more than 60 minutes of additional free online lean training videos, please visit Gemba Academy and sign up for a free preview account.

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Again, to see part 2 of this video for free please visit Gemba Academy and sign up for a free preview account.

  1. Yatin Ubhaykar

    September 29, 2009 - 4:34 pm

    Ever imagined a world where Change Management would happen in a ‘Single Minute’?

    Single Minute Exchange of Die (SMED) is one of the many lean production methods for reducing waste. It provides a rapid and efficient way of converting the running of the current product to running the next product. This rapid changeover is key to improving flow (Mura (Japanese term). While the phrase “single minute” does not mean that all changeovers and startups should take only one minute, but that they should take less than 10 minutes (in other words, “single digit minute”)
    ‘Change management (or change control)’ is the process during which the changes of a system are implemented in a controlled manner by following a pre-defined framework/model with, to some extent, reasonable modifications.
    There are seven basic steps to reducing changeover using the SMED system:

    1.OBSERVE the current methodology
    2.Separate the INTERNAL and EXTERNAL activities. Internal activities are those that can only be performed when the process is stopped, while External activities can be done while the last batch is being produced, or once the next batch has started.
    3.Convert (where possible) Internal activities into External ones.
    4.Streamline the remaining internal activities, by simplifying them.
    5.Streamline the External activities, so that they are of a similar scale to the Internal ones.
    6.Document the new procedure, and actions that are yet to be completed.
    7.Do it all again: For each iteration of the above process, a 45% improvement in set-up times should be expected, so it may take several iterations to cross the ten minute line.
    What would the seven basic steps to change management be from a SMED perspective?


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