One of the events that we mentored was a SMED (Single Minute Exchange of Dies or Quick Changeover) Event on the Mold Changeover Process in a Casting Area.
The newly formed Operational Excellence (OpEx) was skeptical that they were going to achieve any significant reduction in the Changeover. This was their first SMED event.
We (SSDSI) said that the changeover can be reduced by at least 50% (from 2 ½hours to under 1 hour and 15 minutes). As the 5 day SMED event progressed, the OpEx team started see the Waste that the SSDSI Master Black Belts initially discovered.
The OpEx team exceeded their goal of 30% reduction. The setup was reduced to 50%+ with a range from 55-75 minutes.