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Open toolChangeover Time Analyzer (SMED Calculator)
Break down machine changeover steps into **Internal** (machine stopped), **Convertible** (internal steps that can be externalized), and **External** (machine running) categories to calculate current line downtime, post-SMED target downtime, and bottleneck tasks.
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Enter the inputs, then select Analyze Changeover Time.
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How the Changeover Time Analyzer Works
Paste your observed time-study steps to quantify SMED Stage 1, Stage 2, and Stage 3 downtime savings.
Current Machine Downtime = ∑(Internal_i + Convertible_i); Post-SMED Downtime = (∑Internal_i) × (1 − ParallelSpeedup%/100); Downtime Saved = Current Downtime − Post-SMED Downtime; Reduction % = (Downtime Saved / Current Downtime) × 100.
In Shigeo Shingo's SMED methodology, 'Internal' setup occurs while the equipment is stopped, 'Convertible' steps are currently performed while stopped but can be externalized before/after the stop, and 'External' steps occur while the line is producing.
SMED Changeover Classification & Downtime Reduction Reference Table
How each step category contributes to current line downtime versus post-SMED target downtime.
| Step Category Code | Machine State Today | Counts in Current Downtime? | Counts in Post-SMED Downtime? | Typical Industrial Examples |
|---|---|---|---|---|
| `internal` | Machine **Stopped** | **Yes** (`100%`) | **Yes** (`× (1 − Parallel%)`) | Lockout/tagout, unbolting dies, mounting new rails |
| `convertible` | Machine **Stopped** (today) | **Yes** (`100%`) | **No** (`0%` — moved external) | Fetching tools, pre-heating molds, trial-and-error adjustments |
| `external` | Machine **Running** | **No** (`0%`) | **No** (`0%`) | Returning old dies to rack, staging raw materials |
How to use Changeover Time Analyzer (SMED Calculator) step by step
Enter the values for your scenario, verify the units, and run the calculation.
Enter the inputs
Start by entering the required fields in the Changeover Time Analyzer (SMED Calculator) form above.
Verify units and assumptions
Match each value to the unit or format shown next to the input box before running the calculation.
Run and export your result
Select Analyze Changeover Time, inspect the primary metric and breakdown cards, then use Copy result or Download result.txt.
Worked examples for Changeover Time Analyzer (SMED Calculator)
Compare baseline and alternative runs for Changeover Time Analyzer (SMED Calculator) before exporting the result.
Baseline example
Analyze manufacturing changeover and setup times using SMED (Single-Minute Exchange of Die). Break down internal vs. external steps, parallel savings, and downtime reduction %.
Comparison scenario
Current Machine Downtime = ∑(Internal_i + Convertible_i); Post-SMED Downtime = (∑Internal_i) × (1 − ParallelSpeedup%/100); Downtime Saved = Current Downtime − Post-SMED Downtime; Reduction % = (Downtime Saved / Current Downtime) × 100.
Boundary check before exporting
In Shigeo Shingo's SMED methodology, 'Internal' setup occurs while the equipment is stopped, 'Convertible' steps are currently performed while stopped but can be externalized before/after the stop, and 'External' steps occur while the line is producing.
How to interpret the Changeover Time Analyzer (SMED Calculator) output
Review the calculated output alongside your entered parameters and unit conventions.
In Shigeo Shingo's SMED methodology, 'Internal' setup occurs while the equipment is stopped, 'Convertible' steps are currently performed while stopped but can be externalized before/after the stop, and 'External' steps occur while the line is producing.
SMED Time-Study Verification Checklist
Confirm these three points during your shop-floor observation.
Current Machine Downtime = ∑(Internal_i + Convertible_i); Post-SMED Downtime = (∑Internal_i) × (1 − ParallelSpeedup%/100); Downtime Saved = Current Downtime − Post-SMED Downtime; Reduction % = (Downtime Saved / Current Downtime) × 100. In Shigeo Shingo's SMED methodology, 'Internal' setup occurs while the equipment is stopped, 'Convertible' steps are currently performed while stopped but can be externalized before/after the stop, and 'External' steps occur while the line is producing.
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Open toolChangeover Time Analyzer (SMED Calculator): common questions
Answers about using Changeover Time Analyzer (SMED Calculator) and understanding its results.
What is the difference between Internal and External changeover time in SMED?
Internal setup time covers activities that can only be performed while the machine or production line is completely stopped (such as removing a die or locking out a press). External setup time covers preparation and cleanup tasks that can be completed while the machine is still running the previous or next batch (such as fetching tools, pre-heating molds, or returning old fixtures to the crib).
What is a 'Convertible' step in this Changeover Time Analyzer?
A Convertible step is a task that operators currently perform while the machine is stopped (counting toward current downtime), but which can be shifted to External time during SMED Stage 2—for example, searching for bolts, pre-heating a manifold, or pre-setting stops on a shadow board before shutting the line down.
What does 'Single-Minute Exchange of Die' (SMED) actually mean?
Coined by Toyota industrial engineer Shigeo Shingo, 'Single-Minute' does not mean a 60-second changeover; it means reducing internal machine downtime to a single-digit number of minutes (under 10.0 minutes, i.e., 9 minutes 59 seconds or less).
How does the Parallel Crew Speedup percentage work?
In SMED Stage 3 (Streamlining Internal Setup), remaining internal tasks are shortened using quick-release quarter-turn clamps, standardized die heights, and two operators working simultaneously on opposite sides of the machine. The Parallel Crew Speedup % models this percentage reduction on the remaining non-convertible internal steps.
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