Tennessee MEP · Lean Manufacturing
Reduce equipment changeover time from hours to minutes. SMED (Single-Minute Exchange of Die) increases machine availability, makes smaller batch sizes economically viable, and improves your ability to respond to customer demand.
On-site consultants across Tennessee — Nashville, Memphis, Knoxville, Chattanooga, Jackson, Tri-Cities. No commitment required.
Every changeover contains two types of tasks. SMED works by separating them, then systematically reducing the time spent on each.
Internal tasks
Tasks that can only be done while the machine is stopped.
Removing the old die, installing the new die, making critical adjustments that require the machine to be open and locked out.
External tasks
Tasks that can be done while the machine is still running.
Staging the next die, gathering tools, preheating, preparing paperwork, moving materials into position — all before the machine stops.
The SMED method: Identify every task in the changeover. Separate internal from external. Move as many tasks as possible to external. Then streamline what remains. Most changeovers contain 30–50% of tasks that are being done internally but could be done externally.
Long changeover times don’t just waste machine time. They force a chain of decisions that hurt your entire operation.
Larger batch sizes
If changeovers take 2 hours, you run bigger batches to avoid them. Bigger batches mean more inventory, more floor space, and longer lead times.
Slower response to customers
Large batches mean longer queues. A customer order sits waiting while the machine finishes a batch of something else.
More expediting
When lead times are long, rush orders become the norm. Expediting disrupts the schedule, causes more changeovers, and the cycle repeats.
Startup quality problems
Long, inconsistent changeovers produce more startup scrap. Each changeover is done slightly differently, leading to variation in the first parts off the line.
30–70%
Typical changeover time reduction from a single SMED event.
3–5 days
Typical SMED event duration from observation through standardized new method.
$0
Many SMED improvements require zero capital — just method changes and better sequencing.
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Tennessee MEP consultants facilitate SMED events on-site inside your facility. The process includes video observation of the current changeover, separation of internal and external tasks, redesign of the changeover sequence, implementation of improvements, and standardization of the new method. Consultants are based across Tennessee in Nashville, Memphis, Knoxville, Chattanooga, Jackson, and Tri-Cities.
A typical SMED event takes 3 to 5 days. Day one involves video recording and analysis of the current changeover. Days two and three focus on redesigning the sequence and testing improvements. Days four and five standardize the new method and train the team. Most manufacturers see a 30 to 70 percent reduction in changeover time from a single event.
Manufacturers typically achieve a 30 to 70 percent reduction in changeover time from a single SMED event. This translates to increased machine availability, the ability to run smaller batch sizes economically, reduced inventory, faster response to customer orders, and fewer startup defects. SMED improvements also directly improve the Availability component of OEE.
Start with your bottleneck machine or the machine with the longest changeover time. Reducing changeover time on a bottleneck directly increases plant capacity. If changeover time is forcing you to run large batches to avoid frequent changeovers, that machine is also a strong candidate because SMED will allow smaller batches and lower inventory.
Cost depends on the number of machines and complexity of changeovers being targeted. Many SMED improvements require little or no capital investment since they focus on method changes rather than equipment purchases. Tennessee MEP provides an initial consultation at no cost to assess your operation. Contact a Tennessee MEP Solutions Consultant for a specific estimate.
Tell us about your changeover challenges — we’ll help you find where the time is going and how to get it back.
On-site consultants across Tennessee — Memphis, Nashville, Knoxville, Chattanooga, Tri-Cities and beyond.