Contact Details
Phone: 00 353 (0)90 6471223       Email:


Course Dates

To be verified


Duration: 2 Days

Fee: €795  including course manual.

Single Minute Exchange of Dies (SMED)

Developed by Shigeo Shingo of Toyota, SMED is a method for reducing waste in a manufacturing process. It provides method for managing tear down and setup on a machine, necessary to convert from manufacturing the current product to running the next product. SMED is also used for shortening clean down and line clearance times. Rapid changeover is key to reducing production lot sizes and thereby improving flow.

The workshop involves identifying and implementing improvements to the set-up/changeover process on the client’s machine or series of machines. Attendees will work through a full SMED exercise using appropriate lean tools such as video, process mapping, spaghetti mapping, error proofing and standard work.


Time Day 1 Day 2
08.30 LEAN Principles – the 7 wastes

Introduction to SMED: Toyota video review & discussion

Practical demonstration of SMED on demonstration machine in classroom

Gemba walk and review of potential SMED application at the machine

Documenting the current state: Process/time chart

Improving the process

Brainstorming of ideas: review of opportunity for

  • error proofing
  • tool location
  • shadow boards
  • personnel readiness
  • standardisation

Implementing changes:

Practical work in the area


12.30 Lunch Lunch
13.30 Establishing current SMED performance:

  • Review of video taken of SMED
  • Review of measurements & spaghetti map

Brainstorming of process problems

Analysis potential external activities & internal activities:

  • Identifying hazards
  • Identifying redundancy
  • Identifying complexity
Implementing changes:

Practical work in the area

Control: success measurement, SPC

Closing review with team, action items & responsibilities

Closing Review with managers

16.30 Review & close  Review & close



Learning Objective

At the end of this workshop attendees will…

  • understand the definition of changeover time and how it is measured;
  • know how to use arrange of lean tools to reduce changeover time;
  • have established a robust and standard set-up and changeover process on the machine, and
  • have the ability and confidence to further improve and refine the machine set- up/changeover process on an ongoing basis.



In advance of the workshop the client will:

  • identify the machine or suite of machines on which the changeover exercise will take place;
  • collect data changeovers in the recent past on the machine (by product type/tool type/shift etc.);
  • make a video, if appropriate, of elements of the changeover, and
  • select attendees for the workshop.
  • Guidance will be provided on the data required.


Who should attend?

Operators, technicians, engineers, team leads and general production operatives are the best candidates to attend the 2-day training. The attendees should ideally be those who run the equipment on a daily basis, maintenance and support staff such as engineering and quality personnel. Maximum number of attendees = 8.


7  Centre  Court, Blyry Business and Commercial Park, Athlone.


The course begins at 9.15 am and ends at 5.00 pm both days.

The successful completion of this programme by the learner does not lead to an award, but a certificate of attendance is issued to each participant.

Safety Shoes – Not Required on this course

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