Changeover Reduction (SMED) Workbook

{"Title":"Changeover Reduction (SMED) Workbook","IntroductionHtml":"

Purpose: Capture real operator observations, measure current setup time, separate internal vs. external work, run quick conversion experiments, and record sustainment actions so teams shorten changeovers and increase run time.

This workbook is operator-centered: measure first, try one focused experiment, record results, and lock in the improvement with clear owners and simple standard work. Avoid cutting safety or quality—note any safety or quality concerns and stop experiments if they introduce risk.

","SubmitLabel":"Save Changeover Entry","SuccessMessage":"Saved. You can run another experiment, review past submissions, or export results for team review.","DataType":"SMEDWorkbookSubmission","SchemaVersion":1,"Fields":[{"Key":"changeover_id","FieldType":"text","Label":"Changeover ID or Reference","HelpText":"Short identifier you can use on boards or in shift logs (e.g., LineA-Changeover-2026-08-01)","Required":true},{"Key":"date","FieldType":"text","Label":"Date","HelpText":"YYYY-MM-DD","Required":true},{"Key":"shift","FieldType":"select","Label":"Shift","Required":true,"Options":[{"Value":"day","Label":"Day"},{"Value":"swing","Label":"Swing"},{"Value":"night","Label":"Night"}]},{"Key":"line_or_cell","FieldType":"text","Label":"Line / Cell / Machine","HelpText":"Where the changeover occurred","Required":true},{"Key":"product_or_job","FieldType":"text","Label":"Product / Job","HelpText":"Part number or job name"},{"Key":"batch_size","FieldType":"number","Label":"Batch size (units)","HelpText":"Enter numeric batch size if relevant"},{"Key":"baseline_total_minutes","FieldType":"number","Label":"Baseline total changeover time (minutes)","HelpText":"Measured total minutes from last good part of previous run to first good part in new run. Use a stopwatch and record real time.","Required":true},{"Key":"baseline_internal_minutes","FieldType":"number","Label":"Baseline internal work minutes","HelpText":"Minutes of work that must be done while machine stopped (internal). If unknown, estimate then refine by tracking tasks."},{"Key":"baseline_external_minutes","FieldType":"number","Label":"Baseline external work minutes","HelpText":"Minutes of work that can be done while the machine is running (external). Should be less than or equal to total."},{"Key":"internal_tasks_notes","FieldType":"textarea","Label":"Observed internal tasks (brief list)","HelpText":"List each internal task on its own line. Optionally include estimated minutes, e.g. 'Remove die — 4 min'"},{"Key":"external_tasks_notes","FieldType":"textarea","Label":"Observed external tasks (brief list)","HelpText":"List tasks that could be done off-line or prepared in advance."},{"Key":"waste_and_delays","FieldType":"textarea","Label":"Key wastes or delays observed","HelpText":"Examples: searching for tools, waiting for parts, manual alignments, adjustment loops, missing fasteners"},{"Key":"safety_quality_check","FieldType":"yesno","Label":"Any safety or quality risk observed that must be addressed before experimenting?","HelpText":"Select Yes to pause and record concerns. Experiments shouldn't compromise safety or product quality.","Required":true},{"Key":"separation_actions","FieldType":"checkbox","Label":"Separation and preparation ideas to try (check one or more)","Options":[{"Value":"tool_kit","Label":"Create a pre-packed tool kit or trolley"},{"Value":"pre_stage_materials","Label":"Pre-stage materials/fixtures near machine"},{"Value":"convert_fasteners","Label":"Convert to quick fasteners / SMED-type clamps"},{"Value":"parallel_work","Label":"Organize parallel tasks for an assistant to do while machine stops"},{"Value":"use_checklist","Label":"Use pre-setup checklist to reduce searching"},{"Value":"standardize_parts","Label":"Standardize tooling/holders to reduce adjustments"}]},{"Key":"priority_scale","FieldType":"scale","Label":"Priority / expected impact","HelpText":"How valuable is this changeover to reduce? (1 low — 5 high)","ScaleMin":1,"ScaleMax":5,"Required":true},{"Key":"experiment_number","FieldType":"text","Label":"Experiment name or number","HelpText":"Short name for this experiment run (e.g., 'ToolKitTrial-1')"},{"Key":"experiment_hypothesis","FieldType":"textarea","Label":"Hypothesis","HelpText":"What do you expect to change and by how much? e.g., 'If we pre-stage tooling and use a tool kit, total time will fall by 6 min.'","Required":true},{"Key":"experiment_steps","FieldType":"textarea","Label":"Experiment steps (clear, short)","HelpText":"Step-by-step actions to run the experiment. Keep it simple and repeatable."},{"Key":"experiment_owner","FieldType":"text","Label":"Experiment owner (name)","HelpText":"Who runs and records the experiment?"},{"Key":"experiment_result_notes","FieldType":"textarea","Label":"Result notes","HelpText":"Observed outcome, unexpected issues, safety or quality notes."},{"Key":"measured_total_after_minutes","FieldType":"number","Label":"Measured total changeover time after experiment (minutes)","HelpText":"Measure the same way you measured baseline. If you couldn't measure, leave blank."},{"Key":"measured_internal_after_minutes","FieldType":"number","Label":"Measured internal minutes after experiment","HelpText":"If you measured internal/external split, record here."},{"Key":"time_saved_minutes","FieldType":"number","Label":"Time saved (minutes)","HelpText":"Baseline total minus measured total (auto-calc not available here — enter observed difference)."},{"Key":"quick_win_1_desc","FieldType":"text","Label":"Quick win #1 — description","HelpText":"A small change you can lock in quickly (short description)"},{"Key":"quick_win_1_owner","FieldType":"text","Label":"Quick win #1 — owner","HelpText":"Who will own making this permanent?"},{"Key":"quick_win_1_due","FieldType":"text","Label":"Quick win #1 — target date","HelpText":"YYYY-MM-DD"},{"Key":"quick_win_2_desc","FieldType":"text","Label":"Quick win #2 — description","HelpText":"Optional"},{"Key":"quick_win_2_owner","FieldType":"text","Label":"Quick win #2 — owner"},{"Key":"quick_win_2_due","FieldType":"text","Label":"Quick win #2 — target date"},{"Key":"sustainment_actions","FieldType":"textarea","Label":"Sustainment actions (what to standardize)","HelpText":"Examples: update standard work, add tool kit photo, include step in shift handover, train 2 backups."},{"Key":"standard_work_location","FieldType":"text","Label":"Where will the new standard work be stored?","HelpText":"Document name, shared drive path, or location in THE"},{"Key":"measurement_frequency","FieldType":"select","Label":"How often will you re-measure this changeover?","Options":[{"Value":"daily","Label":"Daily for first week"},{"Value":"weekly","Label":"Weekly for first month"},{"Value":"monthly","Label":"Monthly"},{"Value":"on_change","Label":"When process or tooling changes"}]},{"Key":"attachments_note","FieldType":"textarea","Label":"Photos, sketches, or attachments (notes)","HelpText":"Describe photos or sketches taken and where they are stored (e.g., 'photo1.jpg saved to LineA/SMED folder')."},{"Key":"followup_required","FieldType":"yesno","Label":"Is follow-up action required?","HelpText":"Select Yes to ensure a follow-up is assigned."},{"Key":"followup_owner","FieldType":"text","Label":"If yes, follow-up owner (name)"},{"Key":"followup_due","FieldType":"text","Label":"If yes, follow-up due date (YYYY-MM-DD)"},{"Key":"notes_for_team","FieldType":"textarea","Label":"Notes for team review or Kaizen meeting","HelpText":"Short summary to read aloud during the review."},{"Key":"permission_to_share","FieldType":"yesno","Label":"OK to share this submission across site/toolkit?","HelpText":"Enable sharing so other teams can learn."}]}