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The top-performing EMS providers—Jabil, Flex, Sanmina, Benchmark, Zollner, and Asteelflash—consistently focus on a foundational Lean manufacturing methodology known as SMED (single-minute exchange of die) to reduce equipment setup and changeover times to under 10 minutes. The four SMED pillars:
- Offline feeder preparation
- Feeder cart exchange systems
- Barcode/MES verification
- Dedicated setup technicians
These four changes alone typically deliver 60–80% of total achievable setup time reduction before more advanced automation is even considered. The biggest opportunity in EMS setup reduction is transforming setup from a machine-centered activity into a logistics-centered process where materials, feeders, programs, and tooling arrive at the line fully validated before the previous job ends. This shifts the setup from reactive execution to planned exchange, which is the essence of SMED.
How does a smaller EMS company develop a SMED profile similar to the big guys? Let’s explore some specific ways to reduce changeover time.
Reducing SMT Changeovers From 60–120 to 15–40 Minutes
This example roadmap is based on a hypothetical high-mix EMS operation running multiple SMT lines with frequent product changeovers. Beginning with a rather typical baseline for changeovers, let’s outline how a six-phase, six-month optimization process, following SMED, might roll out.
To continue reading this article, which appeared in the July 2026 SMT007 Magazine, click here.
