Video SMED Analysis — How Recording Processes Cuts Machine Changeover Time
Video SMED Analysis — How Recording Processes Cuts Machine Changeover Time
In manufacturing, a machine only makes money when it is running. Every minute a production line stands idle due to a changeover—adjusting the line for a new product type—represents a direct financial loss. This is why in Lean Manufacturing, the SMED (Single-Minute Exchange of Die) methodology is crucial, aiming to reduce changeover times to a single-digit number of minutes (under 10 minutes).
Traditional SMED implementations rely on an engineer observing the process with a clipboard and stopwatch. However, this method has significant limitations. Modern plants are utilizing video SMED analysis—recording the entire changeover process and analyzing it frame-by-frame. This is the fastest, most precise way to identify waste (Muda) and optimize OEE.
💡 Key Takeaways (TL;DR)
Why Stopwatches and Clipboards Are Not Enough
Classic workstation observations with a stopwatch in hand come with several challenges:
- The Observer Effect: When operators feel the pressure of an engineer standing over them with a stopwatch, they may work unnaturally fast or make mistakes due to stress.
- Lost Details: An observer cannot write down every micro-movement, misplaced tool, or second where the operator hesitates over the next step.
- Lack of Objectivity: Discussions often arise between engineers and operators regarding how a specific step was actually performed.
Video analysis removes these barriers. The camera is an objective observer. The recording can be paused, rewound, and analyzed together with the operator at the workstation. It is not a tool to monitor employees, but a collaborative way to find process improvements.
Step-by-Step: How Video SMED Analysis Works
Step 1: Record the Current State (As-Is)
A professional video crew records the changeover process. Typically, 2 to 3 cameras are used: one captures the overall workstation layout and operator movements (walking for tools, returning), while another records close-up details (tightening bolts, setting parameters on the control panel).
Step 2: Frame-by-Frame Analysis and Step Classification
Lean engineers and operators watch the footage together. They classify all activities into:
- Internal Activities: Steps that can only be performed while the machine is stopped (e.g., swapping a mold).
- External Activities: Steps that can be done while the machine is still running (e.g., preparing the new mold, gathering wrenches).
Waste, such as searching for an Allen wrench for 2 minutes, is immediately visible and undeniable on video.
Step 3: Waste Elimination and Optimization
Using the video analysis, improvements are implemented: converting internal tasks to external ones, standardizing tools (e.g., replacing bolts with quick-release clamps), or implementing specialized changeover carts (Shadow Boards).
Step 4: Record the Standard (To-Be)
Once improvements are implemented, the optimized process is recorded. This video becomes the new standard. It is used to train other operators and shifts, ensuring everyone performs the changeover in the same, fast way.
Business Benefits: What the Factory Gains
- Boosted OEE: Reducing machine downtime by 30 minutes a day on a line producing 1,000 parts per hour yields 5,000 extra products daily without purchasing new machinery.
- Improved Ergonomics: Video analysis helps eliminate unnecessary bending, reaching, or lifting heavy parts, reducing operator fatigue.
- Building a Kaizen Culture: Operators involved in analyzing their own video recordings generate the most ideas for workstation improvement because they feel a sense of ownership over the process.
Case Study:
A plastics processing plant averaged 95 minutes for each injection molding machine changeover. Changeovers occurred 3 times a week, causing nearly 20 hours of monthly machine downtime. Stopwatch-based analyses failed to yield results due to the complexity of the process.
We recorded the changeover from 3 cameras (including a POV camera mounted on the team leader's head). During a 4-hour video workshop, Lean engineers and operators mapped the process second-by-second, identifying 42 minutes of waste (e.g., searching for spacers, redundant steps).
Changeover time dropped from 95 to 38 minutes (a 60% reduction). Monthly downtime was cut from 20 to 8 hours, saving over 14,000 PLN monthly per machine. The recorded video was implemented as the training standard.
Professionalism and Discretion in Video Production
Recording workers on a factory floor requires sensitivity. At Sema Studio, we ensure workers understand the purpose of the recording. Before starting the cameras, we explain to the team that the goal is process and machinery analysis, not personal performance evaluation. This ensures full cooperation, a friendly atmosphere, and highly productive SMED workshops.
Want to cut machine changeover times in your plant and implement professional video SMED analysis? Call: +48 663 393 700 or email us at info@semastudio.pl — we will record the videos your Lean engineers need to optimize your processes.