The SMED machine, designed by CLT and built by Ionline, implements quick changeover principles through a series of seven processes crucial for quality production. Each process involves specific procedures, including preparing connectors and switches, with an emphasis on reducing complexity and recording observations for future improvements. Successful completion of these processes allows for machine operation, followed by a review and enhancement of the setup time and efficiency.

1. THE SMED MACHINE
By João Paulo Pinto for CLT VALUEBASED SERVICES, 2015 ©

2. THE SMED MACHINE © 2015
THE MACHINE ITSELF
 It was designed by CLT and build by IOnline;
 It was conceived to put the concepts of quick
changeover into practice.

3. TO PREPARE THIS MACHINE IN ORDER TO PRODUCE
QUALITY PRODUCTS YOU NEED TO SUCCESSFULLY
EXECUTE SEVEN PROCESSES (STEPS).
GOOD LUCK!
PROCESS 3
PROCESS 4
PROCESS1
PROCESS 5
PROCESS 6
ZeroForceConnector
Plug Sub D25
Plug Sub D9
DIP Switch
Pulse switch

4. GENERAL SWITCH
PROCESSCONCLUDEDWITHSUCCESS
ERROR SIGNAL
GENERAL TIMER
TIMER

5. THE PROCESSES
“Fall seven times. Stand up eight.”

6. THE SMED MACHINE © 2015
READY TO MAKE YOUR FIRST CHANGEOVER?
 Make sure the timer is on;
 You may need some tools to help you;
 Take notes along the changeover;
 Record ideas that may help us to reduce complexity and setup time.
 Take some pictures that may be used as future memory;
 Discuss the solutions and implement them;
 Discuss the results!

7. THE SMED MACHINE © 2015
PROCESS 1
 To prepare this process you need to prepare the ZFC40
(Zero Force Connector) so that energy can flow
to Process 2;
 To do so, keep this code in mind, you will need it to make
energy flowing:
2  3  9  14  17
 Off you go!

8. THE SMED MACHINE © 2015
PROCESS 2
 This DIL (dual inline) connector needs to be fit so that the energy can
flow to the next process;
 This is the right sequence to prepare this process:
D G I K a b

9. THE SMED MACHINE © 2015
JUST TO REMEMBER THE ALPHABET…

10. THE SMED MACHINE © 2015
PROCESS 3
 In this process two pulse buttons need to be pressed. It is quite simple!

11. THE SMED MACHINE © 2015
PROCESS 4
 This processes uses a DIP Switch
that needs to be prepared.
 The operations manual of this
machine had a missing page in this
process so you need to find the
position of only two switches…
1on, 2off, 3off, 4on, 6on, 8on.

12. THE SMED MACHINE © 2015
PROCESS 5
 Plug Sub D9
 This the simplest process as
only one plug needs to be
involved;
 Why don’t you give it a try?

13. THE SMED MACHINE © 2015
PROCESS 6
 Now it is time to prepare the 6th process: Plug
Sub D25!
 To work properly you need a key to be inserted in
this process;
 The key can not be directly inserted in the Plug
Sub D25;
 You need to prepare a “bridge” so it can work
properly;
 Use the materials provided to do so…
ERROR!

14. THE SMED MACHINE © 2015
The “blue wires” are to be
consumed during the process,
ie: every time you need to
prepare this process new wires
need to be mounted…

15. THE SMED MACHINE © 2015
PROCESS 7
 After successfully concluded the previous six processes this machine gives
you a limited amount of time to prepare the seventh process;
 If you fail to setup this process you need to start all over again from
process 1 to 6;
 This process was normally prepared by an old lady that is now retried and
no one knows exactly how she managed to put the process right. Maybe it
was her experience or the feminine intuition…
 The next picture depicts one rare moment of the process well prepared and
have been used ever since as a guide/reference to prepare this process.

16. THE SMED MACHINE © 2015
Consider this the
“correct position” of
the POTENTIOMETERS

17. THE SMED MACHINE © 2015
DID YOU MANAGE TO PUT IT WORKING?
Good, it is now time to improve it…
and document it as well

18. THE SMED MACHINE © 2015
LET’S ANALYSE THE RESULTS
INITIAL SETUP:
 TOTAL TIME TO PREPARE THE MACHINE: _______ min
 TOTAL RESETS _______ 
 COMMENTS, SUGGESTIONS AND WHAT CAN BE CHANGED?
[…]
FINAL SETUP:
 TOTAL TIME TO PREPARE THE MACHINE _______ min
 Main improvements made?
 Lessons learned?

19. THE SMED MACHINE © 2015
THANK YOU SO MUCH FOR YOUR ATTENTION
JOÃO PAULO PINTO, Eng
mgt@cltservices.net
+351.936.000.079
www.cltservices.net