AboshSMED reduces changeover time by separating work that needs a stopped machine from work that can be prepared while it runs. Observe the complete changeover, move preparation outside the stopped period where safe, then simplify the remaining tasks. Measure from the last good part to the next verified good part so a faster restart does not conceal extra adjustment or scrap.
Less production time lost to setup
Clear preparation and handover tasks
Startup quality kept in the changeover measure
Agree on the start and finish
Use the last good part of the outgoing run and the first verified good part of the next run. Record safe shutdown, cleaning, adjustment and inspection as well as mechanical setup.
Observe several changeovers. Different products, crews and equipment conditions can reveal tasks that one demonstration misses.
Separate stopped work from preparation
Internal tasks require the machine to be stopped. External tasks can be done before or after that interval while production runs. Classify tasks by the actual safety and process requirements, not by where you would like the time to appear.
Preparing tools and checking material in advance can help. Moving a task to another crew or delaying it until after restart does not remove its cost or risk.
Simplify what still needs the stop
Look for repeated adjustment, searching, unclear roles and avoidable movement. Fixed references, ready-to-use tooling and a clear sequence may reduce the work, subject to engineering and safety approval.
- Observe
Record each task and its timing during real changeovers.
- Separate
Identify which tasks truly require a stop.
- Prepare
Move suitable work outside that interval without shifting unsafe work elsewhere.
- Simplify
Reduce unnecessary adjustment, motion and waiting.
- Verify
Check first-good quality, total work and repeatability.
Check what the recovered time buys
Recovered time may allow smaller batches or more available capacity. Check demand and the line constraint before treating every saved setup minute as extra shipped output.
Keep cleanup, maintenance and verification requirements in the new sequence. A trial must not bypass approved safeguards.
Keep the sequence usable across shifts
Make preparation, roles, settings and first-good approval clear. Recheck difficult products and less experienced crews. When setup time drifts, investigate the task that changed rather than repeating a stopwatch exercise.
A related example from Abolfazl
Follow the scheduling decision after a shorter changeover.
In English, on founder Abolfazl’s personal blog. This is related reading, not an independent technical source.
Practical checklist
- Use a last-good-to-first-good boundary.
- Observe more than one changeover.
- Keep adjustment and startup scrap visible.
- Separate internal and external tasks.
- Check safety before moving work.
- Count preparation labor and displaced work.
- Check the effect on the line constraint.
- Verify the sequence across crews and products.
FAQ
FAQ
Sources and further reading
Authoritative references used to research and verify this guide.