Lean Manufacturing & Operations worked example

SMED Time Savings with current changeover time of 75 min: a worked example

This scenario runs the smed time savings calculation on the strong side: current changeover time of 75 min, with every other input held at its documented default. Use this calculator to quantify the production time recovered from a SMED project. Convert saved minutes into additional units, fewer overtime hours, or capacity for more product variants.

The inputs for this scenario

  • Current changeover time: 75 min (raised for this scenario; the documented default is 30)
  • Improved changeover time: 10 min (unchanged)
  • Changeovers per shift: 4 count (unchanged)

Working through the calculation

  • Applying the documented formula (Time Saved = (Current Time - Improved Time) x Changeovers per Shift) to the inputs above produces each figure below.
  • At this operating point the engine returns 61 min / shift for time saved per shift (min), the number this scenario is built around.
  • At this operating point the engine returns 14 value for time reduction per changeover.
  • At this operating point the engine returns 75 value for current total changeover time.
  • At this operating point the engine returns 81.33 % for utilization.

How this compares with the baseline

  • Against the tool's baseline example, where current changeover time sits at 30 min and the headline result is 16 min / shift, this scenario comes in 281% above the baseline at 61 min / shift.
  • Use it immediately after a SMED event to size the recurring capacity gain, or while forecasting the payoff of a proposed setup-reduction effort. Treat this as a target state: the delta against the baseline quantifies what the improvement is worth before you commit to chasing it.

Results at a glance

  • Time saved per shift (min): 61 min / shift (headline result)
  • Time reduction per changeover: 14 value
  • Current total changeover time: 75 value
  • Utilization: 81.33 %

Run it with your numbers

  • Every input above is editable in the live SMED Time Savings calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.