SMED in Practice: How Position Automation Reduces Setup Time for Lean Flexibility
In high-mix manufacturing environments, flexibility is everything. But long setup times can stall production, inflate costs, and disrupt flow.
That’s where SMED: Single Minute Exchange of Dies, comes in. At Position Automation, we design systems that make fast changeovers not just possible, but practical, helping manufacturers unlock lean agility.
What Is SMED?
SMED is a lean methodology developed to reduce setup and changeover times to less than 10 minutes. It’s based on separating setup tasks into:
- Internal activities: Tasks that must be done while the machine is stopped
- External activities: Tasks that can be done while the machine is running
The goal is to convert as many internal tasks into external ones as possible and streamline the rest. By doing so, manufacturers can respond faster to demand, reduce downtime, and improve flow.
How Position Automation Supports SMED
Our factory automation solutions are engineered with SMED principles in mind. Here’s how we help reduce setup time:
- Programmable Operations: Changeovers are handled through software, not manual adjustments.
- Quick-Change Tooling: Modular fixtures and tool holders make swaps fast and repeatable.
- Integrated Sensors: Automatic detection of part dimensions and alignment reduces manual setup.
- Pre-Configured Recipes: Operators can load saved programs for different parts with a single command.
- Minimal Manual Intervention: Automation handles positioning, clamping, and sequencing, no need to reset manually.
Real World Example: Setup Time Slashed
A client producing multiple aluminium profiles needed to switch between part types several times per shift. Previously, each changeover took 20-30 minutes.
With Position Automation’s system:
- Setup time dropped to under 5 minutes
- Operators used pre-loaded programs for each profile
- Tool changes were simplified with quick release mechanisms
- Downtime was reduced, and throughput increased
This wasn’t just a time saver, it became a competitive advantage.
SMED + Automation = Agile Manufacturing
Reducing setup time unlocks:
- Smaller batch sizes
- Faster response to customer demand
- Less inventory
- Higher machine utilisation
At Position Automation, we believe flexibility is the future, and SMED is the key to unlocking it.
Ready to Cut Setup Time?
If setup is slowing you down, it’s time to rethink your approach. With Position Automation, you can reduce changeovers, increase flexibility, and keep your flow moving, no matter how many product variations you run.
Follow us for more lean tools, automation strategies, and case studies that show lean in motion – one setup at a time.
