Workbook

Changeover Reduction (SMED) Workbook

An operator-centered, interactive SMED workbook and experiment log for measuring current changeover performance, separating internal vs. external work, running focused conversion experiments, staging tools and materials, recording observations, and capturing sustainment actions so teams shorten setup time and increase productive run time.

Interactive Tool

Changeover Reduction (SMED) Workbook

Purpose: Capture real operator observations, measure current setup time, separate internal vs. external work, run quick conversion experiments, and record sustainment actions so teams shorten changeovers and increase run time.

This workbook is operator-centered: measure first, try one focused experiment, record results, and lock in the improvement with clear owners and simple standard work. Avoid cutting safety or quality—note any safety or quality concerns and stop experiments if they introduce risk.

Short identifier you can use on boards or in shift logs (e.g., LineA-Changeover-2026-08-01)
YYYY-MM-DD
Where the changeover occurred
Part number or job name
Enter numeric batch size if relevant
Measured total minutes from last good part of previous run to first good part in new run. Use a stopwatch and record real time.
Minutes of work that must be done while machine stopped (internal). If unknown, estimate then refine by tracking tasks.
Minutes of work that can be done while the machine is running (external). Should be less than or equal to total.
List each internal task on its own line. Optionally include estimated minutes, e.g. 'Remove die — 4 min'
List tasks that could be done off-line or prepared in advance.
Examples: searching for tools, waiting for parts, manual alignments, adjustment loops, missing fasteners
Select Yes to pause and record concerns. Experiments shouldn't compromise safety or product quality.
How valuable is this changeover to reduce? (1 low — 5 high)
1.0 10.0
Short name for this experiment run (e.g., 'ToolKitTrial-1')
What do you expect to change and by how much? e.g., 'If we pre-stage tooling and use a tool kit, total time will fall by 6 min.'
Step-by-step actions to run the experiment. Keep it simple and repeatable.
Who runs and records the experiment?
Observed outcome, unexpected issues, safety or quality notes.
Measure the same way you measured baseline. If you couldn't measure, leave blank.
If you measured internal/external split, record here.
Baseline total minus measured total (auto-calc not available here — enter observed difference).
A small change you can lock in quickly (short description)
Who will own making this permanent?
YYYY-MM-DD
Optional
Examples: update standard work, add tool kit photo, include step in shift handover, train 2 backups.
Document name, shared drive path, or location in THE
Describe photos or sketches taken and where they are stored (e.g., 'photo1.jpg saved to LineA/SMED folder').
Select Yes to ensure a follow-up is assigned.
Short summary to read aloud during the review.
Enable sharing so other teams can learn.
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