How One Factory Cut Changeover Time 70 Percent With One SMED Tweak

In this episode, Lucas and Luna break down how a mid-size automotive parts supplier in Ohio cut die-changeover time from 90 minutes to 27 minutes using a single SMED (Single-Minute Exchange of Die) principle. They walk through the specific change: converting internal setup steps to external setup by pre-heating dies offline. The result? 70 percent faster changeovers, 12 percent more uptime, and $1.8 million in annual savings. Lucas frames it as a case study in bottleneck thinking, not just lean theory. Luna pushes back on whether all shops can pull this off without capital investment. They close on the question: what's your equivalent of the pre-heated die? #SMED #LeanManufacturing #ChangeoverReduction #ToyotaProductionSystem #BottleneckAnalysis #OperationalExcellence #ManufacturingEfficiency #DieChangeover #SingleMinuteExchangeOfDie #OhioManufacturing #ProcessImprovement #ContinuousImprovement #BusinessExecution #TheOperatorsManual #FexingoBusiness #BusinessPodcast #DailyDecisions #TacticalWins Keep every episode free: buymeacoffee.com/fexingo