Setup Activities
Internal = machine stoppedExternal = machine running
Activity
Duration
Type
Optimization
Context — optional, for the annual projection
Downtime per changeover
Current
80 min
→
Optimized
−30 min
per changeover
−37.5 % downtime
→
Current vs. Optimized
Internal / External (current)
Only internal activities create downtime.
Internal (downtime)
External (running)
Where does the current downtime go?
80 min of internal downtime, broken down by measure.
Annual projection
production hours gained
capacity recovered
Recommended levers
Related calculators: OEE calculator (availability loss) · Downtime cost calculator
Share & export your result
Print the analysis as a PDF or request a live demo.
In 5 steps
1
List the setup steps
Enter every activity of a typical changeover along with its duration — from preparation to the first good part.
2
Internal or external?
Decide for each step: does the machine have to be stopped (internal), or can it be done while production keeps running (external)?
3
Mark convertible steps
Flag internal steps that, with a little preparation, can be shifted to external — they then drop out of the downtime.
4
Streamline the remaining internal time
For each remaining internal step, estimate how much you can save through standardization, quick-clamp tooling or fixed presets.
5
Project it across the year
Add your changeovers per year and the value per production hour to see the recovered capacity in hours and euros.
The SMED method
SMED brings every changeover down to a single-digit number of minutes. Shigeo Shingo structured the approach into three stages:
Stage 1
Separate
Cleanly distinguish internal and external setup.
Stage 2
Convert
Shift internal activities to external wherever possible.
Stage 3
Streamline
Standardize and speed up every remaining activity.
Before all of this comes Stage 0: observe the current changeover closely and document every step.
Frequently asked questions about setup time & SMED
The key terms and methods around setup time reduction — briefly explained.