Guide to Changeover Time in Manufacturing is essential reading for FMCG producers looking to improve packaging line efficiency. Changeovers—whether switching formats, materials, or SKUs—are often underestimated, but they directly impact production uptime. This guide covers where valuable time gets lost, quick wins to speed up your process, and long-term fixes that deliver lasting results.
Where Does Changeover Time Get Lost in Manufacturing?
Changeovers often involve more than just a swap of parts. Delays happen because of:
Alignment issues: Realigning guides, sensors, andme-consuming without clear indicators.
Manual adjustments: Changing settings on conveyors, labellers, or filling machines takes time and precision.
Searching for tools or documentation: A disorganised workspace adds unnecessary delays.
No standard procedure: Without a consistent method, operators may take longer than needed.
Operator skill gaps: Untrained staff can create bottlenecks and errors.
Quick Wins to Improve Packaging Line Changeovers
You can improve changeover time with a few simple process tweaks:
Operator training: Short refresher courses keep teams sharp and confident.
Organise tools and parts: Use labelled tool boards and keep change parts near the line.
Introduce SOPs: Standard operating procedures help keep tasks consistent and efficient.
Use visual aids: Colour coding, diagrams, or setting markers reduce guesswork.
Pre-stage materials: Have packaging, labels, and tools ready before the change begins.
Operator training: Short refresher courses keep teams sharp and confident.
Long-Term Fixes to Reduce Changeover Time in Manufacturing
For sustained gains, investing in equipment and process improvement is key:
Modular Equipment for Faster Packaging Line Changeovers
Look for machines with tool-free changeovers or modular components that can be swapped easily.
Automating Changeover Settings for Consistency
Modern systems allow for automatic adjustments via touchscreens or pre-set formats, saving minutes with each change. Lean Manufacturing Tools
Using Lean Tools to Optimise Production Changeovers
Techniques like SMED (Single-Minute Exchange of Die) streamline the process by separating internal and external tasks.
Cross-Training Teams to Reduce Changeover Time
Having multiple team members who can handle changeovers ensures flexibility and avoids downtime waiting on specialists.
Monitor Packaging Changeover Time with OEE Tools
Use downtime tracking or OEE systems to understand how long changeovers really take and where the slowdowns occur.
Get Expert Help with Packaging Line Changeovers
At Packserve Limited, we help manufacturers implement smarter systems and processes outlined in this guide to changeover time in manufacturing. From optimising conveyor systems to implementing smart line upgrades, we help manufacturers reduce downtime and improve overall packaging efficiency.
Learn more about the Single-Minute Exchange of Die (SMED) method to reduce changeover time.
Need help improving your changeover process?
📞 +44 (0) 1254 760 123
📧 info@packserve.co.uk
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