ForgeShiftCompass
Process and FlowPractice C2

SMED (Single Minute Exchange of Die)

Single Minute Exchange of Die is a structured approach to changeover reduction — separating internal steps (machine down) from external steps (machine running) and standardising the routine so equipment is back to running parts in minutes, not hours.

  • Assessment3 questions
  • Templates3
  • Root causeISHIKAWA-6M

What world-class looks like

Changeovers are fully documented, internal and external steps separated, and total changeover time reduced by at least 50% from baseline.

How mature is your operation?

These are the questions Compass asks for this practice, and the levels it scores you against.

Current changeover documentation

Video and time study of the current changeover.

Is your current changeover process documented and timed?

Level 1 → 5World class at level 4

  1. No documentation — each operator does it differently
  2. Informal understanding of the steps; not written or timed
  3. Steps documented but timing not measured consistently
  4. Full video recording and time study completed for baselineWorld class
  5. Baseline documented; waste classified; improvement targets set

Internal/external separation

Move steps from internal (machine down) to external (machine running).

Have you classified which changeover steps must be done with the machine stopped versus which can be done while it is still running?

Level 1 → 5World class at level 4

  1. All steps done with machine stopped — no separation
  2. Some steps informally moved outside the changeover window
  3. Classification attempted but not systematically applied
  4. Formal internal/external classification; external steps moved before changeoverWorld class
  5. All preparatory work completed before machine stops; internal steps minimised

Standardised changeover procedure

Visual SOP at the machine with time targets per step.

Is there a written, standardised procedure for performing changeovers?

Level 1 → 5World class at level 4

  1. No written procedure
  2. Informal checklist used by some operators
  3. Written procedure exists but may be out of date
  4. Current, accurate SOP for changeover with time targets per stepWorld class
  5. Visual SOP at machine; regular audit of compliance and time

Where to start

  • SMED workshop + video analysis

    Process · L1→L2 · Low complexityCloses · Current changeover documentation

  • AI-pre-populated changeover analysis for your machine

    Process · L1→L2 · Low complexityCloses · Internal/external separation
Root-cause methodISHIKAWA-6M

Before this, you need

Next steps

Scoring your operation against SMED (Single Minute Exchange of Die) takes a few minutes and needs no account.

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