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Achieving Lean Changeover

Putting SMED to Work

By John R. Henry

Productivity Press – 2013 – 205 pages

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  • Add to CartPaperback: $43.95
    December 7th 2012


Defined as the total process of converting a line or process from one product to another, changeover will not only help your organization improve quality and flexibility, but it will save thousands and sometimes even tens of thousands of dollars per hour.

Achieving Lean Changeover: Putting SMED to Work is about the practical implementation of the single minute exchange of die (SMED) philosophy developed by Shigeo Shingo at Toyota. Although the book is principally about changeover of manufacturing, packaging, and assembly processes, the general concepts and examples are also applicable in lighter industries that require turnover of processes—including airlines, hospitals, operating rooms, and food service.

Filled with practical examples, the book shares proven methods that can help you convert changeover downtime to productive uptime. It explains why reducing changeover time is important financially and provides a structured methodology to help you identify and implement improvement opportunities.

The author addresses both the machinery issues with changeover/ SMED and the associated operational issues such as costs, waiting times, material movement, documentation, and product/component design. He also devotes a chapter to discussing, in detail, how to calculate the cost of changeover downtime, an area that remains a mystery to many.

Taking a holistic approach to changeover, the text includes a chapter devoted to organizing changeover improvements, keeping them on track, and developing and implementing a formal changeover reduction program. Presenting time-tested methods and practical examples from a variety of industries, it offers you the opportunity to reduce changeover time and cost and provide your organization with the flexibility needed to better satisfy your customers in three important dimensions: product variety, responsiveness, and price.





The 3 Ups

Changeover Time



Importance of Changeover

Pit Stops

History of Changeover

Tactic or Strategy?

The ESEE Concept

Changeover Costs

Knowing Your Costs Is Critical


Tangible Costs of Changeover

Lost Production

Lost Capacity

Reducing Changeover Times Creates Additional Capacity

Impact on Inventory

Labor Costs

Product and Material Losses

Intangible Costs

Response to the Customer

Capacity Utilization


Stress on People, Machines, and Systems

Reduced Innovation


Standard Operating Procedures

Cleaning Is Inspecting

Graphical SOPs

Writing the SOP

Electronic SOPs



Product Design


Quality Clearance

Schedule Production Weak to Strong

Building Design

Separate Clean and Dirty

Don’t Clean Unused Equipment

Batch Versus Continuous Processing

Label Position



Quick Connectors


Servo Motors

Machine Covers

Eliminate Conveyor Rail Adjustment

Multiple Photoeyes

Kit Manufacturing

Preset Timing Adjustments

Movable Motor Mounts

Sprockets and Gears



Smooth Surfaces for Cleaning




Machine Cabinets




No Tools

Hand Knobs and Levers

Quick-Acting Knobs and Levers

Spring-Lock Collar



Magnetic Locking

Vacuum Mounting

Tool-less Plunger Mount

Quarter-Turn Fasteners

Tool Changers

Toggle Clamps

Conical Cylinder Locks

Interrupted Threads

Slots and Keyholes

C Washers

One-Touch Guide Rail Adjustment

Single-Point Adjustment (Double Lead Screw)

Captive Washers

Unitary Lane Spacers

Asymmetric Parts

Scissor Jacks

Changepart Identification



Material Handling

Changepart and Tool Handling

Standardized Components


Duplicate Components


Dual Rollstands






Scribe Marks



Thickness Gauge

Leaf Gauge

Digital Indicators

Micrometer Adjusters

Adjusting Stops and Jacking Screws

Use the Force


Develop and Implement a Program

Process or Project?

Forming the Team

Starting the Team

Who Performs Changeovers

Getting to Work



Author Bio

John Henry is widely known as the Changeover Wizard for his work in making changeover time disappear. His company,, has assisted many companies in a wide variety of packaging, assembly, processing, and other manufacturing industries since its founding in 1996.

After a nearly eight-year stint in the US Navy, John went to work for Alcon Laboratories as maintenance supervisor, eventually rising to manager of Facility Operations. He left to purchase Automation Sales, a company dedicated to the design, sale, installation, and service of automated packaging, assembly, and manufacturing machinery.

In the early 1990s, John realized that changeover was not a necessary evil and could be improved. He began helping some of his machinery clients and was born. Since then, has provided training and consulting assistance internationally to a variety of companies in a variety of industries.

John Henry has master’s degrees in industrial management, interpersonal relations, and business education. John has been a classroom and online adjunct instructor at the Southern New Hampshire University Graduate School of Business since 1982. He teaches packaging technology at the Polytechnic University of Puerto Rico.

John has published many articles in the industry press and is a frequent speaker at national packaging conferences. He was previously a contributing writer for Food & Beverage Packagingmagazine. He is currently a contributing writer for Packaging Digest. John’s other books include Machinery Matters(2011) and The Handbook of Packaging Machinery(in press).

John may be contacted at He is always interested in discussing changeover.

Name: Achieving Lean Changeover: Putting SMED to Work (Paperback)Productivity Press 
Description: By John R. Henry. Defined as the total process of converting a line or process from one product to another, changeover will not only help your organization improve quality and flexibility, but it will save thousands and sometimes even tens of thousands of dollars per...
Categories: Business, Management and Accounting, Industrial Engineering & Manufacturing, Lean Manufacturing