Dates: To be verified.

Duration: 9.15 am 5.00 pm daily

Location: 7 Centre Court, Blyry Business and Commercial Park, Athlone, Co. Westmeath. N37 RT29

Accreditation: Certificate of attendance

Full Fee: €795 including course manual.

Programme overview

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.

* Alternatively this course can be run in a company. Please contact us for in-house rates.

Safety shoes are needed for this course.

Who is the course for

The attendees should ideally be those who run the equipment on a daily basis e.g. maintenance, and support staff such as engineering and quality personnel. It is also suitable for operators and team leads. Maximum number of attendees = 8.

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.

Course Content

Day 1 :

  • 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
  • Review of video taken of SMED
  • Review of measurements & spaghetti map
  • stablishing current SMED performance:
  • Brainstorming of process problems
  • Analysis potential external activities & internal activities:
  • Identifying hazards
  • Identifying redundancy
  • Identifying complexity
  • Review & close

Day 2:

  • 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
  • Implementing changes:
  • Practical work in the area
  • Control: success measurement, SPC
  • Closing review with team, action items & responsibilities
  • Review & close

Follow on courses:

  1. Lean Immersion one-day workshop
  2. Lean six sigma yellow belt two-day workshop
  3. Statistical Process Control (SPC) two-day workshop

Trainer Profile

Richard Doyle, BEng (Chemical Engineering), GE Certified Six Sigma Black Belt and Lean Master

Richard has 20+ years of engineering and operations management experience at a senior level, with organisations such as Seagate and General Electric, in Europe and Asia. He is a GE certified six sigma black belt and is trained as a lean master.  As a consultant, Richard adds value in the areas of strategic planning, R&D roadmap development, site level capital management and capital strategy skills, equipment installation, commissioning and production release, and productivity improvement. He facilitates practical workshops on overall equipment effectiveness (OEE), total productive maintenance (TPM) and quick changeover (SMED).  He is an experienced and motivational project leader, mentor and trainer.

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