In today’s business environment there is an increasing need to become more agile to accommodate the unique needs of your customers. One of the best tools to increase flexibility and agility is the use of SMED methodology. SMED stands for "single minute exchange of die". SMED reduces setup times so that you will be able to accommodate shorter lead-times and higher variety of products while increasing profit margins.

“The aspect of Enna’s SMED training program that impressed me the most was the level of detail and
loyalty to the Facilitator that is incorporated into this package… For me, it’s just extraordinary.”
Shaunne Murray
General Manager, Canaropa Inc.

Enna’s SMED Quick Changeover Training Package provides all the information, materials, and techniques needed to effectively lead your own SMED Quick Changeover Program. As all of Enna’s Solution Packages, the Quick Changeover training package is action oriented using a mixture of training room learning and shop floor implementation. Enna knows that for your Quick Changeover Program to be effective it has to be successful over time. Therefore, our package is structured around a full five-day training schedule, and provides the materials needed to facilitate and implement SMED principles to ensure successful set up reduction. All of this ensures you will have the structure to make sustainable setup reduction a reality.

Quick Changeover Training Outline

1. Lean Strategy to Increase Agility

• Introduction to the Workshop
• The History of Quick Changeover - SMED
• The 7 Wastes of Operations
• The Role of Quick Changeover in Total Improvement
• The 5S's and Quick Changeover

2. Quick Change Over Methodology

• The Components of Analyzing SMED
• Changeover Activities - Internal Tasks
• Changeover Activities - External Tasks
• Internal Changeover Solutions
• External Changeover Solutions

3. Workshop Structure and Activities

• The Steps of the SMED Workshop
• The Analysis Process and Use of Forms
• Teams for the Workshop
• Procedure Review

4. SMED Worksheets and Assessment Form

• The SMED Workshop Forms
• The SMED Self-Assessment Sheet

The SMED Quick Changeover Solution Package contains the following:

• SMED: Facilitator Guide (1) – A comprehensive, easy to use Facilitator Guide for helping you train employees on SMED.
• SMED: Preparation Guide (1) – This guide, included with the purchase of the Solution Package, contains a systematic approach to preparing and executing successful SMED workshops. It helps the Facilitator (trainer) prepare for the event and is a reference manual for timing, scheduling, and the overall flow of the workshop.
• SMED: Facilitator Digital Media CD (1) – Designed using Flash technology, the presentation is a cut above anything designed in PowerPoint. It is the latest technology in presentation format, using dynamic formatting and projection of image and content.
• SMED: Participant Workbook (8) – Designed with the participants in mind, this workbook will be used during the workshop and retained for reference. These workbooks combine information, illustrations, key questions, and space for taking notes. It includes a self-assessment form to test understanding of principles communicated during the training portion of the workshop.
• Motion Diagram Form (1) – An 11x14 pad of forms to record motion and transportation during the setup observation portion of the workshop.
• Changeover Observation Form (1) – An 11x14 pad of forms. This form records and identifies each step of the setup including internal and external times, as well as observations during this portion of the workshop.
• Setup Combination Worksheet (1) – An 11x14 pad of forms for benchmarking and developing the new changeover standard. This form lists the steps and graphs the setup to visually show the new standard setup.
• Overview of Lean: 7 Waste Observation Form (1) – An 8.5 X 11 pad of forms used during the Setup Observation portion of the workshop to record observations made by the participants onto one document.
• 5S: Red Tag Register (1) – An 11x14 pad of forms that logs all items identified when red tagging.
• 5S: Red Tags (50) – These oversized Red Tags are designed with usefulness in mind. Large enough to record information but small enough to be useful, they allow for the control and structure of the sort step of 5S. Each Red Tag has been pre-wired for ease of use.
• 5S: Poster (1) – A full color visual aid to be used during training and posted in work areas as a reference to the 5S Principles.
• 7 Wastes of Operations: Poster (1) – A full color poster to be used during training and posted in work areas to remind staff to continuously eliminate the 7 Wastes of Operations.
• Commandments for Continuous Improvement Poster (1) – A full color poster to support and be the cornerstone of your SMED Workshop. It encompasses the fundamental philosophy behind SMED while reminding participants how to problem solve as a team.
• Rules for Quick Changeover Poster (1) – A full color poster derived from Shigeo Shingo and Hiroyuki Hirano’s commitment to SMED and JIT. It summarizes the principles of Quick Changeover in a large colorful format and can be place in the training room or specific department.

What is SMED or single minute exchange of die(s)?

• A methodology pioneered by Shigeo Shingo for reducing the changeovers of production machinery from producing product A to producing product B to less than ten minutes.

Why should my company perform set up reduction using Enna’s Quick Changeover program?

• Reducing setup times can benefit your company by:
• Reducing WIP and lot sizes
• Reducing finished goods inventory
• Increasing equipment utilization/yield
• Improving profitability without new capital equipment purchase

May I have my purchasing department create a Purchase Order (PO) for the Quick Changeover Solution Package?

• Yes, Enna accepts company purchase orders. Please fax the PO to +1 905 481 0756.
• If you would like, Enna has created order forms that are easy to use.

What is in your Quick Changeover package?

• Our package includes one Facilitator Guide, one digital media CD, one workshop Preparation Guide, eight Participant Workbooks, 4 different posters, 50 - 5S Red Tags, one Red Tag Register, and three pads of Quick Changeover forms.

I am the Continuous Improvement Manager in my facility; how will your package help me do my job?

• The Quick Changeover Solution Package will assist in:
• Training employees
• Involving your employees
• Creating ownership of future Quick Changeover activities to sustain results
• Enna’s Quick Changeover program is easily scalable and reusable. The Quick Changeover Refill Packs may be used to expand your Quick Changeover program and repeat the workshop with other machine/line setups.

Why should we internalize our Quick Changeover initiative?

• For any process improvement initiative to be successful your employees must go beyond just knowing the principles, they must practice them daily. Using Enna’s Quick Changeover program allows your employees to take ownership of improving changeovers.

Should I have a workbook for each participant?

• Enna recommends purchasing a Quick Changeover Participant Workbook for each person involved in order to maximize their experience. The workbook is integral to the presentation and workshop as it provides insight, suggestions, asks key questions and includes a self-assessment form to solidify retention of main concepts. It also allows employees to document their experiences, and may be used as a reference tool after the training and workshop has ended.

Why is Quick Changeover important?

• World-class companies are performing Quick Changeover to reduce WIP,lot sizes, and finished goods inventory. This allows organizations to be more responsive and adaptable to customer demand.

Why should I use Enna’s Quick Changeover Solution Package instead of other Quick Changeover products?

• Enna products are high quality and provide the greatest value for your dollar. Other companies’ products do not compare in quality, format of information and/or are not designed for the actual implementation and sustaining of a Quick Changeover program.

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