On-site consultants · Nashville · Memphis · Knoxville · Chattanooga · Jackson · Tri-Cities
SMED / Quick Changeover
for Tennessee Manufacturers
Reduce equipment changeover time from hours to minutes. SMED (Single-Minute Exchange of Die) increases machine availability and improves your ability to respond to customer demand.
We start with a no cost Gemba walk. No commitment required.
Recognize These Operational Patterns?
If any of the following are familiar, a structured SMED implementation is likely to deliver measurable improvement.
SMED Questions, Answered
What is SMED (Single-Minute Exchange of Die)? +
SMED is a lean methodology for reducing the time it takes to switch a machine or production line from one product to another. The name comes from the goal of achieving changeovers in single-digit minutes — under ten minutes. It was developed in the Toyota Production System and has since been applied across virtually every manufacturing industry. The core technique is separating tasks that must be done while the machine is stopped from tasks that can be prepared in advance while it is still running, then systematically eliminating or simplifying what remains.
What is the difference between internal and external tasks? +
Internal tasks can only be done while the machine is stopped — removing the old die, installing the new one, making adjustments that require lockout. External tasks can be done while the machine is still running — staging the next die, gathering tools, preheating, preparing paperwork, positioning materials. Most changeovers contain 30 to 50 percent of tasks that are done internally but could be converted to external. Converting those tasks is where the largest time savings come from.
How long does a SMED event take? +
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 on the floor. Days four and five standardize the new method and train the team on the updated procedure.
Is SMED only for stamping or die-based operations? +
No. Despite the name, SMED applies to any equipment changeover — injection molding, extrusion, packaging lines, CNC machining, printing, food processing, and more. The methodology is the same: separate internal from external tasks, convert as many as possible to external, then standardize what remains. If your operation has changeovers, SMED can reduce them.
What kind of results can we expect, and how quickly? +
Most manufacturers see a 30 to 70 percent reduction in changeover time from a single SMED event. Results are visible immediately — the new method is tested and standardized before the event ends.
30–70% less changeover time
Achieved in a single event. Improvements are standardized and documented before consultants leave the facility.
More machine availability
Less time stopped for changeovers means more time producing. The same equipment handles more SKUs without capital investment.
Smaller, more flexible batch sizes
When changeovers are fast, running smaller batches becomes economically viable — reducing inventory and floor space requirements.
Faster response to customers
Shorter queues and smaller batches mean customer orders move through production faster and with more predictable lead times.
Fewer startup defects
Standardized changeover procedures reduce variation in setup, which directly reduces first-article failures and startup scrap after each changeover.
Less reliance on expediting
When lead times shorten and schedules become more predictable, the pressure to expedite rush orders decreases and production flow stabilizes.
How does Tennessee MEP help me do this?
Our consultants work on-site with your team from initial assessment through the SMED event — video observation, internal/external task separation, redesign and testing of the new changeover sequence, and standardization of the updated method.
We start with a free consultation. Talk to a Solutions Consultant →
Ready to Cut Changeover Time on Your Floor?
Talk to a Tennessee MEP Solutions Consultant. No commitment. No cost to start.