Quick reference poster
Updated · Free to print and share
SMED changeover poster: internal and external work
Changeover time runs from the last good part of one run to the first good part of the next, and single minute exchange of die (SMED) is the method for cutting it. Shigeo Shingo's insight was to separate internal work, which needs the machine stopped, from external work that can be done while it runs, then move work from internal to external, then shorten what remains. This poster shows one changeover worked through the three moves: five tasks, 60 stopped minutes, and the stopped time falling to 42, 30 and 16 minutes as each move is made.
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Four bars of one changeover, the stopped time shrinking from 60 to 16 minutes as external work moves out, internal work is converted and the rest is shortened.The words on the poster
Changeover: stop the clock sooner
Changeover time runs from the last good part of one run to the first good part of the next.
One changeover, stopped minutes at each stage
- Today: 60 min stopped Everything is done with the machine stopped, fetching and paperwork included. Fetch tools and die 12, Paperwork 6, Remove old die 10, Fit new die 14, Adjust and trial 18.
- Separate internal from external: 42 min stopped Fetch, stage and sign off while the machine still runs. Remove old die 10, Fit new die 14, Adjust and trial 18; while running: fetch tools and die, paperwork.
- Convert internal to external: 30 min stopped Pre-set the die on a bench. Standard settings. Remove old die 10, Fit new die 14, Adjust and trial 6; while running: fetch tools and die, paperwork.
- Shorten what is left: 16 min stopped Quick clamps, two people in parallel, tools at hand. Remove old die 5, Fit new die 7, Adjust and trial 4; while running: fetch tools and die, paperwork.
- Film it. Sort it. Then change it. Internal: needs the machine stopped. External: can be done while it runs.
Definitions from the Lean Lexicon (LEI): changeover, SMED. Example tasks and minutes are illustrative.
On the floor
How to use it
- 1
Pin it at the machine with the longest changeovers, next to the changeover checklist.
- 2
Film one changeover and sort every task into internal or external before you change anything.
- 3
Use the example bars to show the team that the first gain needs no spend: it is doing the fetching while the machine still runs.
- 4
Pair it with the free SMED changeover worksheet and changeover checklist.
Which size to print
- 24 x 36 in or A2: a main wall or team board, read from a few metres away.
- 18 x 24 in or A3: a station or notice board. The A3 file also fits 11 x 17 in paper.
- Letter or A4: a clipboard, binder or handout, on any office printer.
Every PDF is vector, so it stays sharp at full size. Nothing runs to the edge of the page, so no bleed is needed.
Sources and notes
The task times are an illustrative example of how the three moves act on a changeover, not a benchmark. Your changeover will have different tasks; the method is the same.
Templates, decks and guides to go with it
- SMED changeover worksheetChangeover steps with times, internal or external, what can move, ideas and before/after totals.
- Changeover checklist25 checks for every changeover, a record of planned and actual times, and a log of changeover time against target.
- Changeover matrix templateA from-to matrix of changeover minutes with the clean each transition needs (allergen, colour, format), and a weekly planner that totals the order and suggests a shorter one.
- Topic: TPM and maintenanceEvery guide we have on the subject, sorted.
- Topic: Lean manufacturing fundamentalsEvery guide we have on the subject, sorted.
A poster reminds. A routine makes it stick.
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