Checklist

Changeover Reduction (SMED) — Step-by-Step Checklist

A stepwise SMED checklist operators and engineers can use during experiments to separate internal and external tasks and test quick fixes.

Interactive Tool

Changeover Reduction (SMED) — Experiment Checklist

Purpose

Use this guided checklist to run focused SMED experiments that shorten changeovers and increase run time. Record the baseline, separate internal and external tasks, convert what you can, run a timed trial, verify results, and capture lessons so improvements persist.

How to use

  • Record a clear baseline sequence (one step per line).
  • Label each step as internal (must be done with machine stopped) or external (can be done while running or prepared beforehand).
  • Design small experiments to convert internal tasks to external or streamline remaining internal tasks.
  • Run a timed trial, verify process quality, and record lessons and owners for follow-up.

Field help will guide you through what to enter. Attach photos and get a teammate to verify results where possible.

Short name describing the change (e.g., 'Tool pre-stage + quick clamp').
Date of the baseline or trial (YYYY-MM-DD recommended).
Who participated (operators, engineers, supervisor).
Which machine, cell, or line this applies to.
Measured time from last good part to first good part at baseline. Use minutes with decimals if needed.
List each step on its own line and mark as [internal] or [external] and include baseline time if known. Example: 'Remove guard — [internal] — 45s'. This helps separate and prioritize steps.
Copy or list the internal steps you will try to convert or streamline (one per line).
Describe the specific changes you will test (what will be done, who, and when). Mention tooling, pre-staging, checklist changes, or SOP updates.
Estimate how many minutes you expect to shave off the changeover with this experiment.
Measured time during the trial after implementing the proposed changes.
Enter baseline minus trial time. (Manual entry — use your calculator or platform reports.)
Did the first-good-part and quality checks meet requirements after the trial?
If verification failed or partial, describe the issue and immediate mitigation.
Note anything that could cause repeat problems (safety, quality, operator fatigue, tooling wear).
What worked, what didn’t, and why. Be concise and specific so others can replicate.
List concrete next steps with an owner and due date (e.g., 'Update SOP — Alex — 2026-09-10').
Select any support the team will need to standardize the change.
How urgent is standardizing this change?
Note any photos, videos, or attachments and where they are stored (e.g., local network folder, phone, maintenance system).
Hints to improve the next run (who to involve, what to change).
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