quickchangeover

Quick Changeover, also known as Single Minute Exchange of Die (SMED), is a methodology aimed at reducing the time it takes to switch a production process from one product to the next. The primary goal is to dramatically decrease setup times, which are the periods when a machine or line is not producing salable product due to the changeover process. By minimizing these downtime periods, manufacturers can increase production flexibility, reduce lot sizes, improve product quality, and ultimately lower costs.

The SMED methodology typically involves a systematic approach divided into several stages. First, the current changeover process is observed and analyzed in detail, often through video recording, to identify all activities involved. These activities are then categorized as either internal or external. Internal activities are those that can only be performed when the equipment is stopped, while external activities can be done while the equipment is still running. The next step involves converting as many internal activities as possible into external ones. Finally, all remaining internal and external activities are streamlined and optimized to reduce their duration. This often includes techniques such as pre-heating dies, using quick-release mechanisms, standardizing tools, and simplifying adjustments. The ultimate objective is to achieve changeovers in a matter of minutes, hence the name "Single Minute Exchange of Die." This allows for more frequent product runs and a more responsive manufacturing system.