Checklist

SMED Quick-Check & Experiment Template

Operator-centered SMED checklist plus an interactive experiment template operators can use to capture steps, separate internal vs. external work, time changeovers with the stopwatch method, run controlled experiments, and record results so improvements stick.

Interactive Tool

SMED Quick-Check & Experiment Template

Purpose

Use this quick-check to capture current changeover steps, separate internal vs. external tasks, spot easy quick wins, and run a small safe experiment to reduce setup minutes. This interactive template saves the experiment record so teams can compare baseline and test runs, surface safety or quality impacts, and create durable standard work.

How to use

  1. Walk through the current changeover and list each step in sequence.
  2. Mark each step as Internal (must occur while machine is stopped) or External (can be done while running).
  3. Look for quick wins: staging, dedicated tools, simple clamps, pre-heating, or parallel tasks.
  4. Time a baseline setup using the stopwatch method (record minutes and seconds).
  5. Design a single focused experiment (change one thing) and record a hypothesis.
  6. Run the experiment for several repetitions, record times and observations, and decide sustain actions.

Stopwatch method tip

Start timing at the first step of the changeover and stop when the line is producing at spec. For reliability, run 3 repeats when possible and record each run.

List each step on its own line. Include who performs it and any tools or parts used. Example: '1) Remove guard - operator A - wrench; 2) Move fixture - operator B - cart'
For each step above, add I or E (internal or external). Example: '1) Remove guard - I; 2) Stage new fixture - E'
List low-cost or low-risk changes to try first (e.g., pre-stage tooling at operator height, color-code clamps, permanent shadow board).
Whole minutes portion of baseline run (stopwatch).
Seconds portion of baseline run (0-59).
Record conditions (shift, operator, part number, extraneous delays) so the baseline is reproducible.
State what you will change and why. Keep it focused on a single variable. Example: 'Pre-stage tooling at operator station will save 45 seconds by eliminating walk time.'
Describe the exact change (who, what, where). Include required materials and any quick instructions for operators running the test.
If yes, provide mitigations and who approved them. Do not proceed without addressing safety/quality concerns.
Describe risk controls, approvals, and monitoring to ensure no compromise to safety or quality. Leave blank if not applicable.
Minutes portion for run 1.
Seconds portion for run 1.
Minutes portion for run 2. Helpful to repeat when safe and practical.
Seconds portion for run 2.
Minutes portion for run 3. More repeats increase confidence.
Seconds portion for run 3.
Note delays, surprises, operator feedback, quality checks, or other relevant details.
Describe how test times compared to baseline. Example: 'Baseline avg 8:30; test avg 6:10 => ~2:20 saved per setup.' (You may calculate offline or in your head.)
If the experiment is successful, what standard work, tooling, training, or audits are needed to sustain it? Who is responsible?
Person responsible for running and following up on the experiment.
YYYY-MM-DD or plain text date.
When will you review results and decide whether to standardize?
Add tags to help filter experiments later, e.g., 'Line 2, Part A, Night Shift'.
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