SMED changeover study: measure last good to first good
Use a time observation sheet to separate internal and external work, preserve safe setup steps, and verify a repeatable changeover improvement.
External setup
Changeover preparation that can be performed while the previous production job is running.
Examples can include verified tool kitting or approved material staging when resources, space and process conditions allow. External work still takes effort and can interfere with the current job if poorly planned. Compare total work, elapsed changeover time and startup quality when assessing improvement. See the SMED guide.
See also: Internal setup · SMED · Changeover
Use the concept: Cp, Cpk, Pp & Ppk calculator · Downtime log template · MTBF, MTTR & availability calculator
In depth
Takt time vs cycle time vs lead time: calculate the right clock
A worked shift example separates customer pace, observed process speed and end-to-end delivery time, with practical checks before changing the line.
Automation ROI and payback: a business case operations can verify
Separate installed cost, cash savings, released capacity and recurring expenses, then test a conservative scenario before approving automation.