SMED for optimization of changeover times in an electronics manufacturing workshop: a case study

Purpose In the electronic manufacturing services industry, frequent changeovers in high-mix, low-volume production significantly affect overall equipment effectiveness. Reducing these nonvalue-added activities is therefore essential for improving operational performance and competitiveness. This study aims to reduce changeover durations in a surface-mount technology (SMT) workshop through the structured application of the single minute exchange of die (SMED) methodology, combined with digital monitoring tools. Design/methodology/approach The proposed approach consists of three phases: an initial diagnostic based on time analysis and root-cause identification using Ishikawa diagrams, implementation of SMED through task separation, externalization, parallelization and standardization and performance monitoring using a real-time Power BI dashboard. Findings The results show reduction in average changeover time from 48 min to 18 min in week, corresponding to a 62.5% improvement. This reduction generates annual savings exceeding €600,000 while improving process reliability, traceability and working conditions. Originality/value Rather than proposing a new SMED technique or a new digital platform, this study contributes an integrated Digital SMED framework specifically adapted to high-mix SMT production. The framework links SMED task transformation with intelligent operator-support tools, standardized preparation, real-time performance monitoring and data-driven corrective actions. The study further provides empirical evidence of the mechanisms associated with changeover reduction and demonstrates how digital feedback can support the stabilization and sustainability of SMED improvements.