SMED Changeover Observation Checklist
This checklist is designed to observe and analyze the current changeover process before SMED improvements are introduced. The objective is to understand exactly what happens during a changeover, where time is lost, which activities require the machine to be stopped, and which tasks could potentially be simplified, standardized, or moved outside the downtime window. The checklist should ideally be completed by observing an actual changeover at the workplace, rather than relying only on interviews or documented procedures. The findings can be used as the baseline for: Separating internal and external setup activities, Identifying unnecessary movement and waiting, Reducing adjustment and trial-and-error time, Improving preparation, Simplifying tools and methods, Establishing a future standardized changeover process
This checklist template is designed for manufacturing, development, management, warehousing and focuses on Is the complete changeover process clearly defined from the last good, Has the actual changeover duration been measured using real observatio, Have all individual changeover activities been identified and recorded.
What This Template Covers
Use this template to review Is the complete changeover process clearly defined from the last good, Has the actual changeover duration been measured using real observatio, Have all individual changeover activities been identified and recorded with a structured format that supports consistent follow-up and faster decision-making.
- Is the complete changeover process clearly defined from the last good
- Has the actual changeover duration been measured using real observatio
- Have all individual changeover activities been identified and recorded
Why This Version Is Different
Unlike generic templates, this version is tailored to the maintenance & asset management category, the Basic maturity level, and the workflow of manufacturing, development, management, warehousing.
Template Questions
Showing first 15 rows
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1. Is the complete changeover process clearly defined from the last good product to the first stable good product?
Clauses:
The organization has a clear and consistent definition of when a changeover starts and ends. The observation covers the entire process, including stopping the previous production run, preparation, equipment change, adjustments, startup, testing, and stabilization.
Recommendations:
Define the exact changeover boundaries before measuring performance. Record the timestamp of the last acceptable product, machine stop, key changeover activities, first product, and the point at which stable production is achieved. Avoid measuring only the physical equipment change.
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2. Has the actual changeover duration been measured using real observations rather than estimates?
Clauses:
The organization has accurate data showing how long the changeover actually takes. Timing is based on observed activities rather than planned or reported duration.
Recommendations:
Use a stopwatch, mobile device, or digital observation tool to record actual timestamps for each major activity. Repeat observations across several changeovers to establish a reliable baseline and identify normal variation.
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3. Have all individual changeover activities been identified and recorded in sequence?
Clauses:
The changeover is broken down into individual tasks rather than being treated as one large activity. The sequence makes it possible to identify where time is spent.
Recommendations:
Create a detailed activity list covering preparation, machine stoppage, cleaning, dismantling, tooling changes, setup, adjustments, testing, and startup. Record activities in the order they actually occur, including parallel activities.
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4. Have internal setup activities been clearly distinguished from external setup activities?
Clauses:
The organization understands which activities require the machine to be stopped and which can be performed while the machine is still operating.
Recommendations:
Classify every observed task as: Internal setup - must be performed while equipment is stopped, External setup - can be performed while equipment is running. Pay particular attention to activities currently performed during downtime that could be prepared or completed before the machine stops.
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5. Are required tools, materials, components, and equipment prepared before the machine is stopped?
Clauses:
Operators do not need to search for tools, spare components, raw materials, or other resources after the changeover has started.
Recommendations:
Introduce a pre-changeover preparation checklist or staging area. Verify all required items before stopping the machine and establish a standard location for frequently used changeover equipment.
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6. Is unnecessary operator walking or movement minimized during the changeover?
Clauses:
Operators can access tools, materials, controls, and components with minimal unnecessary movement.
Recommendations:
Observe operator movement and identify repeated walking, searching, climbing, or travelling. Relocate frequently used tools and materials closer to the point of use and establish dedicated changeover locations.
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7. Is there significant waiting or idle time during the changeover?
Clauses:
Operators and maintenance personnel spend the majority of the changeover actively performing value-adding setup activities rather than waiting for people, tools, materials, instructions, or equipment.
Recommendations:
Record every period of waiting and identify the cause. Common causes include missing materials, unavailable maintenance personnel, unclear decisions, equipment cooldown, cleaning delays, or waiting for quality approval. Address recurring causes systematically.
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8. Are multiple people involved in the changeover effectively coordinated?
Clauses:
When several operators, maintenance personnel, electricians, or other specialists participate, their activities are coordinated to minimize waiting and unnecessary sequential work.
Recommendations:
Map who performs each task and identify opportunities for parallel work. Use a clear changeover sequence and assign responsibilities in advance so each person knows when and where to act.
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9. Are changeover tools and equipment standardized and easy to access?
Clauses:
The same or equivalent tools are used consistently, and operators can quickly locate them without searching or improvising.
Recommendations:
Create dedicated changeover tool kits, shadow boards, labeled storage locations, or mobile tool carts. Standardize tools where possible and eliminate unnecessary tool variations.
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10. Are fastening, adjustment, and connection methods designed for quick removal and installation?
Clauses:
Equipment components can be removed, replaced, and secured efficiently without unnecessary bolts, complicated fasteners, or time-consuming manual adjustments.
Recommendations:
Evaluate opportunities to replace conventional fastening methods with quick-release mechanisms, clamps, locating pins, standardized fixtures, or other simplified solutions where technically and safely appropriate.
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11. Is cleaning performed efficiently without unnecessary equipment downtime?
Clauses:
Cleaning activities are clearly defined, efficiently organized, and do not extend the changeover unnecessarily.
Recommendations:
Analyze cleaning activities separately and determine whether some cleaning can be performed before shutdown or while other changeover tasks are underway. Standardize cleaning tools, methods, and responsibilities.
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20 total questions
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