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Fast-changing manufacturing requires organizations to be scalable and adaptable; reducing changeover time is essential for enhancing productivity and staying competitive. Changeover time: the time involved in modifying the manufacturing process from the creation of one product into the creation of a different product, including such actions as setup, tool changes, material setup, etc.
Example of a Changeover Time metric: Changeover time is the total time from the last good part produced in the previous production run to the first good part from the next production run. This involves all preparatory work performed with machines: adjusting fixtures, changing tools, preparing raw materials etc.
The benefits of reduction of changeover time include:
When changeover times are minimized, production can run longer, thus maximizing output.
Faster changeover enables more immediate response to market demand, allowing for efficient small batch sizes to be produced.
Reducing the downtime caused by changeovers cuts down on labor and operational expenses.
If done right, they can massively reduce changeover times. Here are some proven methods:
SMED is a method used in Lean manufacturing, which aims to reduce the time it takes to change over a manufacturing process to a single digit (i.e. under 10 minutes). The process involves:
- Separating Internal and External Setup Activities: Internal activities are undertaken during a machine shutdown and external activities during production. Switching but internal activities to external can greatly reduce downtime.
- Simplifying and Standardizing Setup Procedures: As with our demand creation initiatives, we have simplified, standardized and streamlined setup procedures to eliminate unnecessary steps and create consistency.
Standardized procedures prevent any operator from taking variant approaches. This can be achieved by:
- Unsung Heroes: Documenting Best Practices
- Training Employees: Ensuring all employees are trained in standardized processes.
Harnessing technology can help in simplifying changeover processes:
They can provide digital work instructions, such as dynamic workflow and work instructions – which AI-driven solutions like Stryza provide based on changeovers while guiding operators in that process.
It includes intelligent machines doing some of the work that was previously done by humans.
Routine maintenance of equipment and audits of the process can help avoid surprises that lead to extended changeover times:
- Preventive Maintenance: Keeping machines in top shape for smooth changeovers.
- Process Audits: Twice weekly review of the changeover process to optimize inefficiencies
Adopting such practices results in the following:
- Better Use of Equipment: Maximizing the productive time of machinery.
- Lower Inventory Levels: Allowing for just in time production and less storage of godowns.
- Improved Competitiveness: enabling manufacturers to respond to customer needs quickly and efficiently.
SMED (Single-Minute Exchange of Die) reduces changeover time by (1) reducing setup time by converting (1) converting internal setup activities (performed when the machine is stopped) into external ones (performed while the machine is running) (2) Streamlining & standardizing operations for faster changeover.
Digital work instructions, task automation, and data analytics in real-time embody some of the possibilities to reduce changeover time, and technology plays a very relevant role here. For example, Stryza’s AI-powered solutions seamlessly suggest workflows that help direct operators through efficient changeovers.
Changeover procedures should be examined and updated regularly, which can be annually at least, every time equipment is added or changes are made to the process, or inefficiencies are identified to promote continuous improvement and adaptability in fast developing manufacturing requirements.
These strategies help manufacturers reduce their changeover time, giving them more productivity, flexibility and cost-effectiveness. Utilizing solutions, such as Stryza’s AI-powered digital work instructions, can immensely optimize the processes while simultaneously encouraging continuous improvement initiatives out on the shop floor.
Book a free demo of our application and see how it can take your manufacturing operations to the next level.
