SMED changeover reduction checklist (Interactive)

{"Title":"SMED changeover reduction checklist","IntroductionHtml":"

Purpose: Use this operator-centred checklist to measure and reduce changeover time using SMED techniques: separate internal and external steps, try quick experiments, capture standard work, and record sustainment actions. This interactive form saves a discrete changeover record you can review, compare, and use to scale improvements.

How to use: Fill out the top fields before the changeover (line, machine, product). Record start and end times and enter measured minutes. Mark external preparation items that were staged, describe internal steps, and record any quick experiments you run. Assign an owner and a measurement plan so wins stick.

","SubmitLabel":"Save changeover record","SuccessMessage":"Changeover record saved. You can repeat this form to build a history of changeovers, compare experiments, and drive standard work.","DataType":"SMEDChangeoverRecord.v1","SchemaVersion":1,"Fields":[{"Key":"changeover_id","FieldType":"text","Label":"Changeover ID","HelpText":"Optional reference or ticket number."},{"Key":"line","FieldType":"text","Label":"Line / Cell","HelpText":"e.g., Line A, Cell 3","Required":true},{"Key":"machine","FieldType":"text","Label":"Machine / Station","Required":true},{"Key":"product","FieldType":"text","Label":"Product / Part","Required":true},{"Key":"operator","FieldType":"text","Label":"Primary operator","Required":true},{"Key":"date","FieldType":"text","Label":"Date","HelpText":"YYYY-MM-DD","Required":true},{"Key":"shift","FieldType":"select","Label":"Shift","Required":true,"Options":[{"Value":"morning","Label":"Morning"},{"Value":"afternoon","Label":"Afternoon"},{"Value":"night","Label":"Night"}]},{"Key":"start_time","FieldType":"text","Label":"Changeover start time","HelpText":"HH:MM (24-hour)","Required":true},{"Key":"end_time","FieldType":"text","Label":"Changeover end time","HelpText":"HH:MM (24-hour)","Required":true},{"Key":"total_minutes","FieldType":"number","Label":"Measured total changeover time (minutes)","HelpText":"Elapsed minutes from start to end","Required":true},{"Key":"external_preparation","FieldType":"checkbox","Label":"External preparation completed before stop","HelpText":"Check items that were staged or made ready before stopping the machine","Options":[{"Value":"tools","Label":"Tools staged and organized"},{"Value":"parts","Label":"Parts staged and labeled"},{"Value":"fixtures","Label":"Fixtures / jigs staged"},{"Value":"documents","Label":"Work instructions & checklists available"},{"Value":"wrenches","Label":"Common hand tools positioned"},{"Value":"lockout","Label":"Lockout/tagout & permits ready"},{"Value":"cleaning","Label":"Cleaning supplies ready"}]},{"Key":"internal_steps_summary","FieldType":"textarea","Label":"Internal steps (standard work summary)","HelpText":"List each internal step and sequence. Operators: paste your standard work or write short bullet points.","Required":true},{"Key":"internal_minutes","FieldType":"number","Label":"Measured internal work minutes (minutes)","HelpText":"Portion of total time that is internal (machine stopped)","Required":true},{"Key":"parallelization_possible","FieldType":"yesno","Label":"Can internal steps be parallelized?","HelpText":"Would two operators or simultaneous tasks reduce internal time?","Required":true},{"Key":"quick_wins_tried","FieldType":"checkbox","Label":"Quick experiments or fixes already tried","Options":[{"Value":"parallel_clamps","Label":"Parallel clamps"},{"Value":"quick_disconnects","Label":"Quick disconnects for utilities"},{"Value":"tool_presets","Label":"Tool presets and shadow boards"},{"Value":"preload_parts","Label":"Preload parts onto fixtures"},{"Value":"template_gauges","Label":"Template gauges / go-no-go checks"},{"Value":"one_point_adjustments","Label":"Move to single-point adjustments"}]},{"Key":"experiment_description","FieldType":"textarea","Label":"Experiment description (if running an experiment)","HelpText":"Describe the change you want to test and how you'll measure its effect."},{"Key":"experiment_type","FieldType":"select","Label":"Experiment type","Options":[{"Value":"clamps","Label":"Parallel clamps"},{"Value":"disconnects","Label":"Quick disconnects"},{"Value":"pre-staging","Label":"Parts / tool pre-staging"},{"Value":"parallel_teams","Label":"Parallel teams"},{"Value":"standard_work","Label":"Standard work / training"},{"Value":"other","Label":"Other"}]},{"Key":"expected_saving_minutes","FieldType":"number","Label":"Expected time saved (minutes)","HelpText":"Estimate of how many minutes this experiment will save."},{"Key":"observed_saving_minutes","FieldType":"number","Label":"Observed time saved (minutes)","HelpText":"Measured difference after the experiment."},{"Key":"acceptance_criteria","FieldType":"number","Label":"Target changeover time to accept the improvement (minutes)","HelpText":"If observed total <= target, consider change accepted."},{"Key":"standard_work_created","FieldType":"yesno","Label":"Has standard work been created or updated?","HelpText":"If yes, link or reference the standard work location in your domain."},{"Key":"owner","FieldType":"text","Label":"Improvement owner (name)","HelpText":"Who will maintain changes and train others?","Required":true},{"Key":"training_needed","FieldType":"yesno","Label":"Is training required to sustain change?","HelpText":"Mark yes if operators need training."},{"Key":"measurement_plan","FieldType":"textarea","Label":"Measurement & sustainment plan","HelpText":"How will you monitor the change (who, what, when, where)? Example: measure 5 changeovers/week for 4 weeks."},{"Key":"immediate_actions","FieldType":"textarea","Label":"Immediate next actions and blockers","HelpText":"List who will do what next and any obstacles (tools, approvals, parts).","Required":true},{"Key":"notes","FieldType":"textarea","Label":"Notes, observations, risks, safety considerations","HelpText":"Record any safety or quality notes that affect the changeover."},{"Key":"operator_confirmation","FieldType":"text","Label":"Operator confirmation (name)","HelpText":"Operator who completed this record."}]}