Reducing Changeover Time Through SMED Methodology: A Review and Case Application in Beverage Bottling
Reducing Changeover Time Through SMED Methodology: A Review and Case Application in Beverage Bottling
Nishchay Selot
Abstract
Changeover time is a significant source of non-value-added waste in manufacturing, directly impacting overall equipment effectiveness and profitability. Single Minute Exchange of Die (SMED), developed by Shigeo Shingo, provides a systematic methodology for reducing changeover durations by distinguishing internal from external activities and converting or eliminating tasks wherever possible. This paper reviews SMED literature across food and beverage, automotive, garment, and packaging industries, synthesizing findings from ten peer-reviewed sources. A primary case study applies SMED to a product changeover at a milk beverage bottling plant using Tetra Pak aseptic filling equipment. The intervention reduced average changeover time from 40 minutes to approximately 28 minutes - a 30% reduction - yielding annualized savings of $230,000. Results confirm that SMED consistently delivers changeover reductions of 18% to 65% across industries, with the greatest gains achieved through internal-to-external conversion supplemented by operator engagement.
Keywords: SMED, changeover time reduction, lean manufacturing, beverage bottling, setup optimization