Strong technological development and competitive pressures have driven organizations, especially in the automotive sector, to implement strategies that enhance operational efficiency, thereby improving their performance. One critical topic is the reduction in machine setup times, where the Single Minute Exchange of Die (SMED) methodology has shown significant potential. However, SMED is mostly approached as a technical tool to improve efficiency, but with limited emphasis on how its implementation can be improved through the implementation as a participatory and strategic approach based on structured workshops. This study addresses this gap by presenting the planning and execution of systematic SMED workshops to engage cross-functional teams in setup time optimization. The field tests were conducted in an automotive manufacturing firm. The setup time on a selected injection line was reduced from 48:30 to 29:41 min (38.8% improvement). Its broader applicability was validated with improvements up to 53.66% across other machines. This study contributes a practical, replicable framework for SMED implementation that integrates structured training workshops into continuous improvement processes in automotive manufacturing and highlights the importance of employee engagement and standardized work in a Lean approach.
Sousa et al. (Wed,) studied this question.