SMED - How to reduce set-up times

Originally this technique was developed for Die changes (Single Minute Exchange of Die) but the general approach is applicable on any costly set-up time.

First of all, a set-up is a process so we can use the Kaizen approach. However, the focus on minimising the equipment down time allow us to add other, less costly resources such as labour to the process.

We talk about "inner" and "outer" set-up time.
Inner time is spent on activities while the machine is stopped.
Outer time is spent before it is stopped and after it is started.

To summarise the SMED technique:

1. Move inner time operations to outer time

2. Add all necessary resources that can further reduce the inner time

3. Apply Kaizen work on the remaining operations to minimise inner and total time even further

A very visual example is a racing pit stop