Changeovers are a common part of business operations and can often be a source of frustration when they are inefficient. Changeover time is the amount of time it takes to switch from producing one product to another. It is an important factor when calculating production costs and is often a key element to maintaining efficient operations and meeting customer demands. This blog post will explore the concept of changeover time, detailing its importance, the various ways it can be measured, and the strategies that can be employed to improve it. Additionally, we will discuss the implications of an inefficient changeover and how it can affect the overall productivity of an organization. By taking into consideration the topics discussed in this blog post, businesses can avoid costly downtime and maintain their competitive advantage in the market.
What are the benefits of reducing changeover time?
Typically, cutting down on changeover time has a lot of advantages, like giving a manufacturing facility more time for other processes. High changeover times can reduce the amount of time teams have each day to produce products and finish other tasks, which can be especially beneficial for businesses that produce a lot of products. Because minimizing changeover time frequently results in finding ways to improve the process, reducing changeover time can also facilitate the transition between production processes. Teams can then apply these techniques to subsequent switchovers and continuously enhance their performance.
What is changeover time?
The term “changeover time” describes the period of time that elapses while a team modifies the machinery or production lines in a manufacturing facility to begin producing a different good. The tasks involved in the process of changeover typically include determining which tools or machine parts are required for the production of a particular product and replacing surplus parts on manufacturing equipment with the necessary ones. The team can begin keeping track of time as soon as the production of one product ends and stop the measurement once the production of the next product starts in order to accurately measure a manufacturing plant’s changeover time.
For instance, a dental supply company might swap out tools for attaching bristles to brushes for tools that fill tubes with toothpaste if they switch from manufacturing toothbrushes to toothpaste tubes. Additionally, they might need to change materials and machine settings. These tasks must be finished within the company’s changeover time.
How can you reduce changeover time?
There can be many ways to reduce changeover time. Here are a few of the most popular strategies for speeding up changeovers:
Prepare materials before starting changeover
Gathering and preparing the materials a team might require prior to changeover is one of the simplest ways to shorten changeover time. When the time comes, this can assist manufacturers in organizing themselves and enabling them to quickly begin the changeover process. For instance, a team can decide which machine parts, tools, and manufacturing materials they will need for the new product and gather them in one location if they know a changeover is scheduled for the following day. Then, when production of the current products stops, they can start the transition process right away.
Ensure all equipment is functional at the start of the day
Reduced changeover time can also be achieved by ensuring that any manufacturing equipment a team intends to use is in good working order. This is due to the fact that once changeover has started, if a team later discovers a defective part or a malfunctioning machine, they frequently have to stop production until they can fix the issue and may even have to restart the changeover process. In order to prevent this, it can be beneficial for a team to check all of the tools and equipment they intend to use at the start of the workday so they can make any necessary repairs before production begins.
Use a checklist
Another excellent way to speed up changeover is by using a checklist, which can cut down on the amount of time a team needs to spend figuring out what needs to be done. A manufacturing team can use a checklist for the changeover process to list every task they need to complete and provide a space for people to check each task off as they complete it. The team can easily refer to the list and complete each task once the changeover starts if a checklist is made at least one day before it happens.
There are numerous ways to create a checklist, including with a pen and paper or a mobile app, but it can be useful to make sure that everyone on a team can access the checklist, whether it be digitally or in a prominent location at work.
Create reference materials
Reference materials can be things like tool logbooks and notes outlining how to set up machines. While many workers in a manufacturing facility may be aware of where materials are kept and how to set up equipment, having a set of uniform guidelines that everyone can refer to can help eliminate confusion and guarantee that everyone is aware of the same things. Because everyone can consult the logbook or notes, it can also cut down on the amount of time that a team spends asking one another for instructions or where something is.
Once a team has produced reference materials, it can be very beneficial to put them in a place where everyone can easily access them, like online or posted on a wall at work.
Organize used materials at the end of changeover
Employees should always return any tools or supplies they use to their storage areas as soon as they’re finished using them. However, because a team might need to stop or move to different locations within a plant to put tools or materials away, this can lengthen the time that a team spends switching out equipment during the changeover process.
This is why during changeover, it may be best to store products from the previous production process in a designated central location that is close to the production line. Once the switchover is complete, the team can arrange the used items.
SMED: How to do a Quick Changeover
FAQ
What is the meaning of changeover time?
The time between the last good part of one run and the first good part of the next is how changeover time is most frequently defined. The qualifier “good” in the definition is crucial because a successful changeover cannot be considered complete until the new part run satisfies quality standards.
How do you calculate changeover time?
In essence, the number of pieces that run before the change is required divides the time to change. In the example in the video, the changeover time is 600 seconds for 50 pieces, so the cycle time is increased by 12 seconds for each piece.
What is the purpose of changeover?
The process of changing a line or machine from producing one product to another is known as “changeover” in the manufacturing industry. When auto manufacturers retool for new models, changeover times can range from a few minutes to several weeks.
What is a changeover event?
The occurrence of both a Change of Control and a Rating Event is referred to as a Change of Control Triggering Event.
