Tool Change & Setup (SMED)
Standardized setup instead of "a matter of experience".
🏭 PRODUCTION
Every minute of machine downtime is lost productivity. SMED only works if the optimal sequence is followed consistently - and that is usually where it fails.
-25%
setup time
10 vs 25
min variation today
OEE+
measurable improvement
What you document: tool change on the injection molding machine, setting up the stamping die, format change on the packaging line, mounting new fixtures on the CNC - and the SMED logic: external vs. internal setup steps.
⚠️
The trigger - how do you recognize it?
- Setup times vary widely between shifts (10 min vs. 25 min for the same change)
- Your SMED cards have been pinned to the board for 2 years, but nobody follows them
- Your "setup expert" is retiring soon
- New employees take twice as long to set up
ℹ️
How it works with GIRI
QR code on the tool or machine. SMED logic visualized: external steps before setup start, internal steps with a stopwatch. Comparison photos show "this is what correctly mounted looks like", arrows mark torque values and tightening sequences.
💡
The value
- -25% setup time through standardized procedures
- More consistent setup times - less variation between shifts
- OEE improvement in the single- to low double-digit percentage range
- External setup steps moved up front - the machine stands still for less time
💡
Typical users
- Injection molding & forming
- Stamping and press technology
- Packaging lines
- Contract manufacturing with frequent order changes
⚠️
What you want to avoid
- "Setup is a matter of experience" - that is exactly the problem we are solving
- Only showing the optimal sequence - show the typical mistakes too
- Not separating external setup steps - without SMED logic it stays half-optimized
KPI figures are industry benchmarks (REWO, SwipeGuide), not a GIRI guarantee.
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Machine Operation for a New Order → Maintenance & Repair