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Training in Changeover Time Reduction (SMED)

More and more businesses are realizing that in today’s fast-paced and ever-changing world, time is one of the most valuable resources. In a company’s daily operations, the saying “time is money” can be taken quite literally. Every minute of downtime for a production line or a bottleneck machine translates into real financial losses for an organization. That’s why companies seek solutions to make the most effective use of their available time. In manufacturing plants, special attention is given to Non-Value-Added (NVA) activities—those that do not contribute value to the customer. SMED training and workshops offer a powerful way to significantly reduce changeover times and increase the flexibility of the production system. Discover how your company can minimize downtime costs and become more competitive by optimizing changeover times.

DURATION

1 day

LEVEL

Basic

FORM

Closed training with the use of a simulation game

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TRAINING PLAN

1. Basic definitions
2. Data collection and analysis
3. The next stages of the SMED
methodology 4.
Simulation Game 5. Discussion of the results and benefits of SMED

What Is SMED?

SMED (Single-Minute Exchange of Dies) is a methodology designed to reduce machine and equipment changeover times to a single-digit value—below 10 minutes. This approach was developed by Shigeo Shingo, one of the leading experts in Lean Manufacturing. His method consists of the following four steps:

Stage 0 – Current State Analysis

Stage 1 – Separating Internal and External Activities

Stage 2 – Converting Changeovers

Stage 3 – Improving All Operations 

SMED stages

Our SMED workshops are not just about theory—they are primarily focused on hands-on practice. A significant part of the training takes place on the production floor, where participants observe an actual changeover process. The entire team then conducts a detailed analysis and develops a specific implementation plan. Participating in such a structured changeover time reduction training provides numerous benefits:

 

  • Gaining knowledge about changeovers and the SMED methodology.
  • Developing skills in effective data collection for analysis.
  • Increasing employee efficiency and effectiveness.
  • Raising awareness of waste occurring during changeovers.
  • Learning systematic methods to reduce changeover time.
  • Improving employee engagement and their impact on processes.

Day 1 – Workshops

  • Introduction to Lean Management and the Theory of Constraints. lean management and Theory of Constraints
  • Fundamental concepts related to changeovers.
  • SMED methodology - origins
  • Overview of SMED methodology.
  • Stage 0 – Current state analysis (video recording, spaghetti diagram, observation sheets)
  • Stage 1 – Changeover segmentation (internal and external operations, control and function cards, visual management, 5S, standardization)
  • Stage 2 - Changeover transformation (function standardization, advanced work preparation, intermediate clamping devices)
  • Stage 3 - Process improvement tool management, parallel operations, clamps, mechanization)
  • Application of ROI (Return on Investment) for implementation projects
  • Conducting a changeover observation at the Client’s site
  • Initiating changeover analysis

Day 2 – Workshop

  • Updating the work schedule , verification of planned
  • Segmentation of operations from the observed changeover into internal and external
  • Developing new work standards and necessary documentation
  • Analyzing solutions applicable in Stages 2 and 3 (brainstorming, how-how diagram)
  • Planning further implementation actions (timeline)

Day 3 - follow-up

  • Verification of planned actions and update of the work schedule
  • Conducting a current state observation (recordings, analysis) and summarizing the benefits of implemented actions
  • Changeover matrix – input of collected data and information
  • Standardization and continuous process improvement, visual management
  • Planning the next areas for SMED workshops
  • Discussion panel
  • Exam

Reducing changeover time is a team effort that should involve not only production but also support departments. So, who should participate in the SMED training?

 

  • Management Team (production managers, supervisors, team leaders)
  • Maintenance Personnel (mechanics, automation specialists)
  • Production Process Supervisors (process engineers, technologists)
  • Production Operators (machine operators, set-up technicians)
  • Internal Logistics Personnel (dairy operators, Kanban specialists, logistics leaders)

 

This approach ensures that all the necessary personnel gain a better understanding of the need for change and work based on the same, widely recognized method. 

Companies that have decided to implement SMED have observed many tangible benefits:

 

  • Increased machine availability
  • Greater repeatability of the machine changeover process
  • Shorter training times for new employees
  • Reduction in technological scrap during machine start-up
  • The possibility of reducing production batch sizes
  • Increased production flexibility and the ability to plan precisely
  • Shorter lead times

"SMED training allowed us to reduce changeover time from 4 hours to 30 minutes within a few weeks. A great combination of theory and practice!" – Jakub P., Production Manager

 

"Thanks to the SMED workshops, we learned to look at the changeover process in a new way. Highly recommended!" – Magdalena Z., Lean Engineer

 

"Professional approach, lots of practical examples, and tools for immediate implementation." – Marek P., Change Leader

  1. How long is the SMED training?

    The standard training lasts from 2 to 3 days, depending on the company's needs.

     

    1. Are the workshops tailored to the industry and the company's specifics?

    Yes, our trainings are always preceded by a needs analysis and a visit to the production facility, ensuring that the trainer adapts examples and materials to the client's individual requirements.

     

    1. Do participants receive a certificate?

    Yes, every participant receives a certificate confirming the completion of the SMED training.

     

    1. What are the prerequisites for participants?

    There are no special requirements – the training is open to anyone who wants to improve the efficiency of changeover processes.

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