Reduce Downtime: Increase Capacity  

One of the greatest sources of downtime in food processing is the time it takes to setup for the next production run.  A proven technique to help you reduce Setup Time is the Single Minute Exchange of Dies (SMED) developed by Shigeo Shingo a top Toyota Consultant. Shingo was able to reduce the setup time of a 1000ton press from 4 hours to 3 minutes, a major breakthrough for Toyota.  SMED is also known as Quick Changeover, Startup and Changeover Reduction

Setup Time Defined:

Amount of time between the last good piece of the production run to the first good piece of the next.

SMED in a Nut Shell:

1.  Observe and Measure Internal and External Setup Activities
Use a time observation form, stopwatch and video camera to record the current process.


Internal Setup (I):  Activities that must be performed when equipment is stopped or powered down.
External Setup (E):  Activities that can be performed while equipment is running.

2.  Separate Internal from External Setup Activities
Clearly define the roles for further analysis.

External Time: 42min        Internal Time:  35min       


3.  Convert Internal to External Setup Activities
Pick the activities that you know can be done externally and remove them from the internal setup process.

External Time: 57min        Internal Time:  20min      


4.  Improve and Simplify Internal Activities
Eliminate or simplify the time it takes to clean, rinse, adjust, attach etc.  Remove or replace fasteners using clamps and other simple devices when possible.  Apply pins and stops to reduce tuning and tweaking.  Have tools, equipment and procedures near the point of use.

5.  Improve and Simplify External Activities
Shadow Boards and carts can be used to store tools and equipment at point of use.  Always keep the equipment, jigs, tools and fixtures clean and in working condition for the next changeover.  Imagine the difference between a service station and a racecar pit crew.  Pit crews are prepared and have a simple process.

6.  Measure Results
Use a time observation form, stop watch and video camera to record the new process.

7. Standardize
Standardize new process through documentation and training.

8. Celebrate the Success
Buy pizza and report the results.