SMED Mastery for Lean Manufacturing Professionals

You’re under pressure. Production delays are mounting, changeovers are bloating downtime, and leadership is demanding faster throughput with leaner resources. Every minute lost during a changeover is a direct hit to OEE, profitability, and your reputation as a continuous improvement leader.

You’ve tried incremental improvements, but the breakthrough results-the kind that get noticed by executives and fast-track careers-just haven’t materialised. Traditional SMED training leaves gaps. It’s too theoretical, too generic, or too outdated for today’s high-mix, low-volume production environments.

What if you could cut changeover times by 50%, 70%, even 90%, using a proven, step-by-step SMED methodology trusted by world-class manufacturers? This isn’t speculation. The SMED Mastery for Lean Manufacturing Professionals course gives you the exact system used to achieve 84% faster changeovers at a leading automotive assembly plant in Mexico-results delivered in under 90 days.

This course is your bridge from uncertainty to authority. From being reactive to being recognised as the go-to expert who delivers measurable, board-ready improvements. From stuck to future-proof, with a certification-backed skill set that positions you at the forefront of Lean evolution.

You’ll finish with a fully documented SMED implementation plan tailored to your environment, ready for immediate deployment. No abstract concepts-just actionable, structured guidance that turns knowledge into results.

Here’s how this course is structured to help you get there.

Course Format & Delivery Details

Designed for Real Professionals in Real Manufacturing Environments

This is a self-paced, on-demand course with no fixed dates, weekly check-ins, or rigid schedules. You access the material anytime, day or night, from any device. Typical completion takes 12–18 hours, and most professionals see actionable results in under 30 days-many begin applying concepts on the shop floor during their first week.

You receive lifetime access to all course materials. That means ongoing access-even after you complete the course-and every future update is included at no extra cost. As SMED practices evolve, so does your knowledge. Permanently.

The course is mobile-friendly and fully optimised for global 24/7 access. Whether you're at home, on the shop floor, or travelling for work, your progress syncs seamlessly across devices.

Real Support from Expert Practitioners

This isn't a set-and-forget knowledge dump. You get direct, practical guidance through structured instructor support. Submit process challenges, receive implementation feedback, and clarify complex SMED scenarios from Lean experts with 20+ years of cross-industry experience. No AI-generated responses. No automated chatbots. Real human insight, when you need it.

Industry-Recognised Certification & Credibility

Upon completion, you earn a Certificate of Completion issued by The Art of Service. This certification is globally recognised by manufacturing excellence teams, procurement groups, and enterprise continuous improvement offices. It validates your mastery of SMED at an operational and strategic level-enhancing your credibility, internal mobility, and professional market value.

No Risk. No Hidden Costs. No Compromise.

The course pricing is straightforward and transparent-no hidden fees, no subscriptions, no auto-renewals. What you see is exactly what you pay.

We accept all major payment methods, including Visa, Mastercard, and PayPal, for secure, hassle-free enrollment.

If you complete the course and feel it didn’t meet your expectations, you’re covered by our 100% money-back guarantee. That’s how confident we are that this will deliver value to your career.

“Will This Work for Me?” - We Know the Doubts

You might be thinking: “This sounds good, but what if I’m not in automotive? What if my process is too complex? What if I don’t have management buy-in yet?”

This works even if you work in aerospace, medical devices, packaging, or job-shop manufacturing-industries with highly variable changeovers and tight compliance requirements. We’ve had senior process engineers in FDA-regulated facilities use this methodology to reduce sterilisation line transitions by 68%, with full audit trail compliance.

Here’s what Luisa R., a Lean Manager at a Tier-1 supplier, said after implementation: “I used the SMED methodology from this course to redesign our press changeover. We cut setup time from 57 minutes to 19. That’s 38 minutes saved per shift, every shift. My plant manager presented our results to corporate. I was fast-tracked into the Operational Excellence leadership pipeline.”

After enrollment, you’ll receive a confirmation email. Your course access details will be sent separately once the materials are fully activated. This ensures you receive a stable, polished learning experience-no rushed or incomplete rollouts.

The risk is on us. The value is permanently yours.

Module 1: Foundations of SMED and Lean Manufacturing Excellence

• Understanding the Evolution of SMED in Modern Manufacturing
• Defining Internal vs External Setup Activities
• The Link Between SMED and Key Performance Indicators (OEE, Takt Time, Throughput)
• Comparative Analysis: SMED vs Traditional Changeover Practices
• Historical Successes: From Toyota to Global Manufacturers
• Common Misconceptions About SMED Implementation
• Identifying the Cost of Downtime in Your Operation
• The Role of SMED in Supporting Lean Principles
• Setup Waste vs. Other Types of Muda
• Creating a Business Case for SMED in Your Facility
• Engaging Frontline Teams in Changeover Improvement
• Balancing Speed and Safety During Setup
• Understanding the 8 Wastes in the Context of SMED
• How SMED Enables Small Lot Production
• The Impact of Shorter Changeovers on Inventory and Flow

Module 2: Core SMED Methodology and the 8-Step Process

• Step 1: Identify and Document Current Setup Procedures
• Creating a Detailed Setup Process Map
• Step 2: Separate Internal and External Activities
• Tools to Distinguish Internal vs External Tasks
• Step 3: Convert Internal to External Activities
• Pre-Staging and Pre-Heating Techniques
• Pre-Alignment and Pre-Positioning of Components
• Step 4: Reduce Internal Work Through Standardisation
• Developing Visual Setup Guides and Checklists
• Using Jigs, Gauges, and Positioning Aids
• Step 5: Reduce External Work Through Preparation
• Creating a Dedicated External Setup Station
• Step 6: Parallel Operations and Teamwork Setup
• Designing Role-Specific Setup Tasks
• Training for Dual-Function Operator Techniques
• Step 7: Mechanisation and Automation Opportunities
• Identifying Low-Cost Automation Levers
• Step 8: Repeat and Refine – Institutionalising Kaizen
• Establishing Feedback Loops from Operators
• Maintaining Gains Through Standard Work Updates

Module 3: SMED Tools, Templates, and Visual Management

• Designing SMED Project Charter Templates
• Using Setup Time Tracking Sheets
• Developing SMED Stopwatch Analysis Protocols
• Creating Process Flow Diagrams for Changeover
• Designing Setup Scorecards and Dashboards
• Implementing SMED Checklists with Visual Controls
• Photographic Documentation of Setup Stages
• Using Shadow Boards and Tool-Kits
• Colour-Coding and Marking Systems for Quick Identification
• Implementing Floor Markings and Zoning for Setup
• Time Lapse Documentation Without Video
• Using Tactical Light Indicators for Changeover Phases
• Developing One-Page Setup Summaries
• Integrating SMED with 5S for Sustainability
• Visual Work Instructions for Non-Native Language Speakers

Module 4: Data-Driven Setup Analysis and Measurement

• Establishing Baseline Changeover Times
• Measuring Manual vs Machine Downtime
• Conducting Setup Time Stratification
• Using Stop-Start Logging for Process Breakdown
• Analysing Bottleneck Activities in Setup
• Applying Pareto Analysis to Identify Top 20% Time Drivers
• Tracking Improvement with Run Charts and Control Limits
• Calculating ROI for Each SMED Intervention
• Estimating Annual Savings from Time Reduction
• Linking Setup Time to Machine Capacity and Utilisation
• Measuring First-Run Quality After Changeover
• Time-Phased Costing of Operator Labour During Setup
• Estimating Material Waste During Trial Runs
• Quantifying Energy Use During Intervals
• Using Data to Justify Capital Requests

Module 5: Advanced SMED Applications Across Industries

• SMED in High-Mix, Low-Volume Environments
• Handling Frequent Product Changeovers in Batch Processes
• Adapting SMED for Continuous Flow Lines
• Applying SMED in Assembly Operations
• SMED for Injection Moulding and Plastics
• Roll Change SMED in Paper and Steel Manufacturing
• Degree Changeover in Food and Beverage Processing
• Label and Packaging Change SMED
• Changeovers in Cleanroom and Sterile Environments
• Tool Change SMED in CNC Machining
• Dye and Ink Change SMED in Printing
• Die Change SMED in Press and Stamping Facilities
• SMED for Automated Guided Vehicles (AGVs)
• Changeover Planning in Mixed-Model Assembly
• Maintenance Integration into SMED Cycles

Module 6: Changeover Safety, Compliance, and Risk Mitigation

• Integrating Lockout/Tagout (LOTO) into External Tasks
• Safety-Critical Steps in Internal Operations
• Ensuring Compliance with ISO and FDA Requirements
• Documenting Changeover Procedures for Audits
• Preventing Cross-Contamination in Food and Pharma
• Validating Equipment Calibration Post-Changeover
• Using Checklists to Minimise Human Error
• Safety Sign-Off Protocols Before Production Start
• Team Communication During High-Pace Changeovers
• Emergency Stop Integration in Setup Workflows
• Managing Ergonomic Risks in Manual Transfers
• Conducting Risk Assessments for Modified Setups
• Changeover Training for Temporary and Agency Staff
• Creating Legal Traceability of Process Updates
• Audit-Ready Documentation Using SMED Records

Module 7: Operator Engagement and Skill Development

• Building a Culture Where Operators Lead SMED
• Conducting SMED Kaizen Events with Teams
• Developing Multi-Skilled Setup Technicians
• Operator-Led Root Cause Analysis of Delays
• Mentoring Junior Team Members Through Setup
• Using SMED as a Leadership Development Tool
• Feedback Collection Using Structured Interview Forms
• Visualising Operator Ideas on Idea Boards
• Incentivising Setup Time Reduction Without Penalties
• Rotating Roles to Enhance Cross-Training
• Creating Setup Champions Within Teams
• Documentation Ownership by Frontline Staff
• Recording Operator Insights for Continuity
• Conducting Peer Observation and Coaching
• Standardising Knowledge Transfer Across Shifts

Module 8: SMED Integration with Digital Systems and IIoT

• Linking SMED to Manufacturing Execution Systems (MES)
• Digital Checklists and Andon Integration
• Using SCADA Data to Validate Changeover Completion
• Scheduling SMED Windows in ERP Planners
• Automated Changeover Logging via RFID Tags
• Using QR Codes for Tool and Part Location
• Integrating Setup Data into OEE Software
• Alerts for Missed SMED Steps via Andon Lights
• Data-Driven SMED Performance Reviews
• Leveraging Digital Twins for Setup Simulation
• Remote Monitoring of Changeover Progress
• Using AI for Predictive Setup Preparation
• Capturing Step Times in Real-Time Without Video
• Linking SMED Records to Asset Management Systems
• Digitising Work Instructions for Tablets

Module 9: Advanced Techniques for Zero Changeover (One Touch Exchange of Die)

• Principles of One Touch Exchange of Die (OTED)
• Pre-Positioning Equipment Using Linear Guides
• Automated Clamping and Hydraulic Lock Systems
• Rapid Tooling Interchange Using Standard Interfaces
• Modular Dies and Quick-Swap Fixtures
• Pre-Calibrated Sensors and Controls
• Using Stored Program Settings per Product Type
• Automated Parameter Upload via Memory Cards
• Robotic Tool Changers in High-Speed Lines
• Mechanical Indexing Tables for Multi-Station Setups
• Counterbalance Systems for Heavy Tool Handling
• Spring-Loaded Ejection and Alignment
• Air-Cushioned Transfer Systems
• Automated Lubrication and Cleaning Pre-Setup
• Die Storage Racking with First-In-First-Out Logic

Module 10: Cross-Functional Implementation and Leadership

• Engaging Maintenance, Quality, and Planning Teams in SMED
• Aligning SMED with Preventive Maintenance Schedules
• Coordinating Changeover with Material Supply Routes
• Integrating SMED into New Product Introduction (NPI)
• Training Quality Inspectors on Post-Changeover Checks
• Collaborating with Engineering on Fixture Design
• Changeover Metrics Reporting to Senior Management
• Presenting SMED Results with Board-Ready Visuals
• Securing Budgets Using ROI Dashboards
• Scaling SMED Across Multiple Plants
• Developing a Global SMED Center of Excellence
• Creating SMED Standard Work Across Facilities
• Leveraging Best Practices Through Internal Benchmarking
• Establishing SMED Audits and Compliance Reviews
• Designing Incentive Programs for Enterprise Results

Module 11: Sustaining Gains and Continuous Improvement

• Establishing SMED as Part of Daily Management
• Incorporating Setup Metrics into Tier Meetings
• Using Gemba Walks to Monitor SMED Execution
• Re-Baselining After Major Process Changes
• Conducting Refresher Training Annually
• Updating SMED Procedures for Equipment Upgrades
• Handling Staff Turnover with Knowledge Retention
• Using Kaizen Breaks to Re-Optimise Setups
• Monitoring for Process Drift Over Time
• Revalidating Setup Times Quarterly
• Sharing Success Stories Across Departments
• Linking SMED Improvements to Employee Recognition
• Maintaining Documentation in Controlled Systems
• Conducting Cross-Shift SMED Reviews
• Developing SMED Playbooks for Future Leaders

Module 12: Certification, Career Advancement, and Next Steps

• Preparing for Your Final SMED Implementation Project
• Submitting Your Workplace SMED Application for Review
• How Certification is Earned and Verified
• Receiving Your Certificate of Completion from The Art of Service
• Adding Certification to LinkedIn and Resumes
• Leveraging SMED Mastery in Performance Reviews
• Using Certification as a Promotion Accelerator
• Networking with Other Lean Professionals
• Accessing Exclusive Post-Course Resources
• Enrolment Pathways to Advanced Lean and Six Sigma Programs
• Developing Internal SMED Training Programs
• Becoming a SMED Mentor in Your Organisation
• Publishing Case Studies Using the SMED Framework
• Presenting Results at Industry Conferences
• Advancing to Black Belt or Master Black Belt Level