Split changeover into internal and external work.
Use it to cut changeover time. List the changeover steps, mark which can be done while the machine runs, set reduction targets, and it shows stopped time today, after converting and after streamlining.
I is internal (machine stopped). E is external (done while running). Y moves an internal step to external. Reduction % applies to steps that stay internal.
Stage 1 is today: all internal steps. Stage 2 moves steps marked Y to external work. Stage 3 applies the reduction % to what is still internal.
SMED (Single-Minute Exchange of Die) cuts changeover time so you can run smaller batches economically.
A press changeover takes 64 minutes. 22 minutes are spent finding the die, fetching tools and waiting for the crane, which is all work that can be done before the stop. Moving that work to pre-staging and adding locating pins cuts the stop to 26 minutes.
Single-Minute Exchange of Die: changeovers under ten minutes, which is a single-digit number of minutes.
Internal steps can only be done while the machine is stopped. External steps can be done while it is still running the previous job.
Shorter changeovers allow smaller batches, less inventory, more flexibility and more available machine time.