SMED Sustainment and Audit Checklist
This checklist evaluates whether SMED improvements have been successfully embedded into daily operations and sustained over time. The objective is to ensure that improvements achieved during the initial SMED project do not gradually disappear due to changing personnel, equipment conditions, production pressure, or inconsistent management attention. The audit focuses on five key areas: Standardization - Is the improved changeover method clearly defined? Adherence - Are operators consistently following the standard? Performance - Is changeover performance measured and monitored? Capability - Are people trained and competent? Continuous Improvement - Are further opportunities actively pursued? This checklist is suitable for manufacturing operations, production supervisors, Lean teams, maintenance, engineering, and operational excellence teams.
This checklist template is designed for manufacturing, development, management, warehousing and focuses on Is there a clearly documented standard changeover method for the proce, Are changeover activities clearly divided into internal and external s, Are operators consistently following the approved standard changeover.
What This Template Covers
Use this template to review Is there a clearly documented standard changeover method for the proce, Are changeover activities clearly divided into internal and external s, Are operators consistently following the approved standard changeover with a structured format that supports consistent follow-up and faster decision-making.
- Is there a clearly documented standard changeover method for the proce
- Are changeover activities clearly divided into internal and external s
- Are operators consistently following the approved standard changeover
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 there a clearly documented standard changeover method for the process?
Clauses:
The improved changeover process is formally documented and represents the current best-known method. The standard covers the complete changeover sequence from preparation through stable production.
Recommendations:
Create a clear Standard Work document covering task sequence, responsibilities, expected times, tools, settings, safety requirements, and quality checks. Ensure the documented standard reflects the latest approved improvement.
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2. Are changeover activities clearly divided into internal and external setup tasks?
Clauses:
The organization maintains a clear distinction between activities that require equipment downtime and those that can be completed while the equipment is operating.
Recommendations:
Review the classification periodically and challenge whether activities currently performed during downtime can be moved outside the changeover window. Update the standard whenever improvements are identified.
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3. Are operators consistently following the approved standard changeover sequence?
Clauses:
Operators perform changeovers using the agreed method rather than reverting to individual working practices or outdated procedures.
Recommendations:
Conduct periodic observations of actual changeovers. Compare practice against the standard and address deviations through coaching, training, or process improvement rather than simply treating deviations as operator errors.
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4. Is the standard changeover time clearly defined and understood by the team?
Clauses:
The team understands the expected changeover duration and the specific starting and ending points used for measurement.
Recommendations:
Define a consistent measurement method, such as last good product to first stable good product, and communicate the target to all relevant personnel.
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5. Is actual changeover performance regularly measured against the target?
Clauses:
Changeover duration is measured consistently and compared with the established target. Performance data is visible and used to identify deviations.
Recommendations:
Track actual changeover time for each relevant changeover. Use trend charts or visual dashboards to highlight performance deterioration and recurring losses.
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6. Are changeover performance trends reviewed over time?
Clauses:
The organization monitors whether SMED improvements are being maintained over weeks and months rather than only checking individual changeovers.
Recommendations:
Review trends regularly using metrics such as average changeover time, best performance, variation, downtime, and percentage of changeovers completed within target.
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7. Are deviations from the standard changeover process identified and investigated?
Clauses:
Significant deviations are not ignored. The organization understands why the standard was not followed and determines whether the cause is related to people, equipment, materials, methods, or an inadequate standard.
Recommendations:
Use a structured deviation review. Avoid assuming that every deviation is caused by operator non-compliance; sometimes the standard itself needs improvement.
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8. Are the tools, fixtures, materials, and equipment required for changeover consistently available and properly maintained?
Clauses:
Changeover teams have immediate access to all required resources, and dedicated tools or fixtures remain in good working condition.
Recommendations:
Inspect changeover tool kits and staging areas regularly. Replace damaged equipment, maintain dedicated fixtures, and use visual controls to identify missing items quickly.
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9. Are changeover preparation activities consistently completed before the machine stops?
Clauses:
External setup activities are completed in advance, ensuring the machine does not remain stopped while operators search for tools, materials, components, settings, or instructions.
Recommendations:
Use a pre-changeover readiness checklist and periodically audit whether preparation activities are actually completed before machine stoppage.
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10. Are operators and maintenance personnel adequately trained and competent in the standardized changeover method?
Clauses:
All personnel performing changeovers understand the standard process and can execute it safely and consistently.
Recommendations:
Establish formal training and competency verification for changeover roles. Train new employees before independent work and provide refresher training when standards change.
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11. Are visual work instructions and standard changeover documentation available at the point of use?
Clauses:
Operators can easily access current instructions, setup parameters, tool requirements, and sequence information where the changeover takes place.
Recommendations:
Use concise visual instructions, photographs, diagrams, digital checklists, or workstation displays. Remove obsolete versions and ensure the current standard is always available.
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20 total questions
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