Quick Change Over (SMED)

In Field Training

Improving set up time in order to Increase flexibility.

Changeover = Time to Change a from the Last Part of a Production Lot to the First Good Part of the next Production Lot.

Description of a Traditional Changeover

Single Minute Exchange of Die (SMED) is a method developed by Shigeo Shingo and a cornerstone for Just in Time production, it originally looks to reduce the setup time in less than 10 minutes, today this approach is used to improve all kinds of setting activities.

In Field Training: we will learn and practice on the shop floor

Shopfloor activities

Practice the steps of SMED to reduce time on selected processes.

Group Exercises

Learn with participants from other industries and exchange experiences

Case examples

Implementation examples and clear exercises to clarify the method.


Dates: 13-15 March    Location: BOA RBT,  Arad Romania.

Language: Romanian

Who should attend: Senior managers, leaders and  middle managers that are interested on improving the flexiblity on their processes in order to better serve their customers.


Quick setups will enable you to:

  • Reduce the work in process and finish good inventory

  • Produce smaller batches of more varied products

  • Reduce your lead time to serve your customers faster

  • Instill the sense of urgency on your team.


Approach: Participants split into teams to perform activities in the shop floor and practice the concepts, working in real processes with a coaching provided throughout the steps.

Objective: understand the concept and practical implementation of SMED in order to set the foundations for Just in Time production and higher equipment availability.

Skills to be practiced during the workshop:

-The 4 steps method to analyze and improve the Change over process

-How to make easier and streamline any process to reduce the idle time.

-Calculate the savings and impact on reducing the change over time.


Most of the concepts are accompanied by practical exercises or shop floor exercises

  • Lean Management and the need for flexibility

  • SMED background, the cornerstone for Just in Time

  • Calculating the operational benefits from Quick Change over.

  • Flexibility indicator: Every part Every Interval

  • SMED Methodology

  • Activities classification in a Change over

  • Define the set-up Steps

  • Separate Internal from External Activities

  • Prepare all external activities

  • Transform Internal into External Activities

  • Streamline Internal Activities

  • Requirements to enable quick change over

  • Standardization, 5s and Visual Management

  • PDCA approach for reducing the change over time

  • The link to leveled Production and pull system

  • Continuous Improvement

SMED Process

  • 1) Document & classify activities

    Document a “Dry-Run” Setup, and separate Events into Internal Setup and External Setup

  • 2) Transform internal into externals activities

    Convert any internal setup events to external setup events using focused, engineered methods.

  • 3) Streamline internal events

    Standardize activities to simplify, reduce, and Eliminate tasks.

  • 4) Eliminating Adjustments and Trial Runs

    Turn intuition and guessing into data and settings, 100% elimination of trial runs


Host Company

boa logo

Host Company: BOA RBT – Arad, Romania

BOA RBT – Arad Plant

The BOA Group is one of the world’s leading manufacturers for flexible mechanical elements for the automotive and aerospace industry as well as for a wide range of industrial applications.

The headquarters is based in Stutensee, Germany. Today, the BOA Group consists of 15 subsidiaries and shareholdings in 13 countries.

The BOA Group develops, produces and distributes flexible stainless steel components for engine management, exhaust systems, fuel systems and side components for passenger cars and heavy vehicles.

BOA Romania is located in Arad. The plant started its operations in July 2014 producing metal hoses and exhaust gas recirculation pipes for the automotive industry as well as V-clamps for industrial applications.

The BOA Group develops, produces and distributes flexible stainless steel components for engine management, exhaust systems, fuel systems and side components for passenger cars and heavy vehicles.

In the industrial division, the BOA Group delivers flexible elements for applications in the Energy sector, Shipbuilding, Rail and Heavy Engine industry. Customized expansion joints are designed for Petrochemical, Chemical as well as Oil & Gas Pipelines.

Precision metal bellows and ultra clean metal hoses complete the product range and offer high tech product applications in the Vacuum, Semiconductor & Magnet Technology market.


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