SMED (Single-Minute Exchange of Die) is a Lean methodology aimed at drastically reducing the setup or product changeover time in machines and processes. The term “single-minute” refers to the goal of completing changeovers in less than 10 minutes.
In test systems, SMED allows for quickly changing products, firmware, fixtures, or parameters without compromising traceability or quality.
🔧 Why is SMED important?
- Reduces non-productive time between tests
- Increases production flexibility for smaller batches and high variety
- Allows for quicker response to product mix changes
- Decreases the need for intermediate inventories
- Improves OEE and the productivity of the test station
🧩 SMED Steps Applied to Test Systems
- Analyze the current setup
Observe, time, and document each step of the product changeover (software, mechanical, electrical, parameters). - Separate internal and external operations
- Internal: can only be done with the system stopped (e.g., changing a jig)
- External: can be done while the system is running (e.g., pre-loading sequence)
- Convert internal to external whenever possible
- Example: pre-configuring test sequence while another test is running
- Example: fixture with quick coupling or automatic identification
- Simplify and standardize operations
- Digital checklists, standardized connectors, automatic menus by product code
- Eliminate unnecessary adjustments and trials
- Automatic calibration, device identification via QR Code or I²C reading
🔧 How AJOLLY Testing Applies SMED in Industrial Testing
AJOLLY Testing designs test systems focused on quick setup, automated product changeover, and flexibility, using SMED principles from conception.
⚙️ Smart Hardware Solutions
- Fixtures with quick couplings, automatic identification (ID EEPROM, RFID)
- Modular connection interfaces, no need for manual adjustments
- Ergonomic layouts that facilitate access and cable or board changes
🖥️ Configurable Test Software
- Sequences parameterized by product code or label reading
- Auto-detection of firmware, version, model, or serial number
- Dynamic loading of tolerances, limits, and measurement scripts
⏱️ Setup Monitoring and Traceability
- Recording of changeover time and responsible operator
- Alarms for incomplete or inconsistent setups
- Automatic reports with average setup time per station or product
With AJOLLY Testing, SMED is more than a production technique — it is an integrated strategy to make your testing process agile, standardized, and prepared for multiple products with full traceability.