The SMED Quick Changeover Simulation (also known as the Quick Changeover Training Simulation) is one of the top simulation games and brings your team together to learn by playing. It uses standard building blocks, which are sold separately, as the SMED building blocks kit.
This simulation is supported by the SMED Quick Changeover Presentation. We strongly recommend that they are used together during the training session, because this way your team can experience the true power of what they’ve learned.
SMED or Quick Changeover represents the absolute minimum amount of overall time needed to change over from one activity to another.
Overall Time is the elapsed time between the last good part on one run to the first good part on the next run.
The SMED concept originated from a consultant of Toyota in the 1950’s.This systematic approach, which you can try out using our SMED Game, is specifically devised to significantly shorten the changeover time of machinery from hours to “single digit” minutes.
- SMED – Single Minute Exchange of Dies
- Pioneered by Shigeo Shingo
As a training simulation, the SMED quick Changeover Game uses practical demonstrations to reinforce Quick Changeover principles. By using building blocks to mimic a production line, your team can visualize ways to shorten manufacturing time and then apply what they’ve learned to a real-life production setting.
Through ELSE Inc.’s SMED Game, managers and workers are able to realize the importance of quick changeover setups, which promotes reduced idle periods in between equipment conversions. This is done through streamlining the essential steps and eliminating processes that do not contribute to the value of the end product.
If applied consistently across the production floor, SMED concepts will allow companies to produce results faster, and unproductive activities or “wastes” are eliminated.
Just learning the concepts of the SMED Game is not enough to feel a deep sense of understanding, however. By actively experimenting and applying what they’ve learned, in the safe environment of the classroom, yet being able to make mistakes and truly learn what works and what not, the team engages in a new way of Lean thinking that will be very beneficial at the moment when they will actually perform the workshop and put in practice, in the real workplace, what they’ve learned.
- The SMED game consists of building and then switching between two sets of dies/fixtures
- The teams will play 2 rounds. Each round will need to have some pre-requisite work done (i.e. having the machine already built and fixture 1 installed)
- Each team has two members.
- During each round, every team will perform a changeover operation
- One person will go through each step described in the work instructions while the second person will keep track of the timing of each step.
- Together, they will analyze every step and decide on the desired changes.
- The second round will prove the tangible benefits of the SMED process.
How will they manage to change their way of thinking and improve their operational effectiveness?
There’s one way to discover this: Get in the game!
The SMED game is designed for groups of 2 people. If you have more players, just buy more Mega Bloks (micro blocks) or Lego pieces and use the same instructions. It can be seen as a competition between teams.
The purpose of the game is to prove the benefits of using the SMED technique to analyze the current constraints and to reduce the changeover process.
By playing two rounds (assembling robots from Lego, according to the current process and after creating SMED) we will demonstrate how we can increase the throughput while using the same number of people.
- SMED/Quick Changeover Basics
- Introduction of the SMED game
- Play Round 1 – Traditional Changeover
- Apply the SMED techniques
- Play Round 2 – SMED/Quick Changeover
- Discussions based on Results
- SMED Simulation (slides)
- Trainer Manual (footnotes that explain each slide)
- Trainee Manual (presentation slides and space for notes)
- Cell layout
- Operator Work Instructions
Please note: If you already have building blocks or intend to purchase the blocks yourself, please click here for a list of parts required.
The simulation game comes as a downloadable zip file, available upon payment. Includes uneditable PDF and PowerPoint (2007-10) versions of presentation and supporting PDF files.