TL;DR: Reducing changeover time in manufacturing can improve production flow and cost savings. Key strategies include following lean principles, re-engineering processes, training employees, practicing preventative maintenance, and investing in automation.
Main points:
- Changeover time refers to the period required to switch from producing one product to another
- Efficient changeovers minimize downtime and maximize machine utilization
- Strategies to reduce changeover time include:
- Applying lean manufacturing principles (SMED)
- Re-engineering processes to eliminate unnecessary steps
- Training employees to handle multiple tasks and troubleshoot
- Practicing preventative maintenance
- Investing in automation and software
Manufacturers are always on the lookout for ways to improve. Even the smallest changes can have a major impact on streamlining production and helping your products get to market faster.
One area that often poses an opportunity for improvement is changeover time. Reducing the time it takes to switch a manufacturing line or equipment from producing one product to another can lead to enhancements in production flow and cost savings.
For discrete manufacturers dealing with complex assemblies and product variations, changeover time reduction can provide a competitive edge.
The Ins and Outs of Changeover Time
Changeover time refers to the period required to convert a manufacturing system or assembly line from producing one product variant to another. Some factories have low changeover time, with each assembly line always performing a single task. However, this isn’t always the case for discrete manufacturers. Products are distinct and production runs aren’t continuous.
A changeover is not a simple process. It includes the preparation of equipment, tools, and software configurations, as well as the time taken to test and ramp up production to a stable rate of output. It truly accounts for the time between the last product off the line of a production run to the first quality part of the next production run.
Efficient changeover processes minimize downtime and maximize machine utilization. They also make factories more adaptable to changes in the industry that would require a change to the production line.
On the other hand, excessive changeover times can lead to significant bottlenecks. When machines and assembly lines are idle, they are not producing. This directly impacts your bottom line by increasing labor and operational costs per unit produced.
How to Calculate Changeover Time
How do you determine if your changeover time could be better? There are a few changeover time formulas to choose from. This is one of the most straightforward for discrete manufacturers:
Total Changeover Time = Downtime + Adjustment Time + Testing Time
- Downtime: The time when the production line is completely stopped to begin the changeover.
- Adjustment Time: The time taken to make physical changes to the line, such as changing parts or tools, and adjusting settings.
- Testing Time: The time spent making sure the new setup produces the product to the desired specifications.
Manufacturers can pinpoint specific areas where efficiency gains are possible by tracking these individual components. As your production process changes, you should always update your calculations to make sure it remains accurate.
Changeover Time Example
Consider this example of a factory producing complex robotics components. Each product variant might require different components, settings, and testing protocols. With the changeover time formula, you find that the process takes up to two hours due to manual adjustments and extensive quality checks.
After streamlining the process through better tool setups and pre-programmed machine adjustments, the factory reduces the changeover time to just 30 minutes.
How to Reduce Changeover Time in Manufacturing
While the above is just a hypothetical example, reducing changeover time is achievable for many manufacturers. Here are some of the ways you can begin to reduce this important metric and streamline your production processes.
Follow Lean Manufacturing Principles
The SMED (Single-Minute Exchange of Die) system is one of the most effective lean manufacturing tools designed to reduce changeover times. It aims to reduce setup time to under 10 minutes (that’s why "single-minute" is included in the name).
It essentially involves categorizing changeover activities into those that can be done while the equipment is running (external) and those that must be done when the equipment is stopped (internal). Changeover times can be reduced when internal activities are converted to external ones.
Re-Engineer Processes
Of course, one of the best ways to experience a changeover time reduction is by overhauling the process itself. Analyzing the existing changeover procedure and identifying unnecessary steps that can be eliminated or combined is the best way to cut back on waste right away. Simplifying the setup procedures so that fewer tools and configurations are required can also decrease changeover time.
Focus on lean manufacturing principles like the one above when redesigning changeovers.
Train Your Employees
While machines play an important part in production, so do you people. The efficiency of a changeover heavily depends on the skill and speed of the workforce executing it.
Training workers to handle multiple tasks or to troubleshoot common issues can significantly reduce any downtime. They should be familiar with the machinery they work with and be able to help identify any problems or areas of improvement.
Practice Preventative Maintenance
Regular preventive maintenance is critical for minimizing downtime associated with changeovers. This is good practice to avoid unexpected malfunctions and breakdowns that often prolong changeovers.
Being proactive about maintenance benefits every aspect of your manufacturing, from ensuring processes run smoothly to extending the lifespan of your machinery.
Invest in Automation
Advancements in automation and software are shifting the way changeovers are performed in manufacturing. Automated systems can perform many of the manual adjustments required during a changeover. Similarly, modern manufacturing execution software can give you better insight into your factory floor to better predict optimal changeover schedules and procedures based on real-time data analytics.
Ready to streamline your discrete manufacturing processes? Learn how ION can help. Book a demo today.