What is Changeover Time?
Changeover Time is the average time span required for the smooth & effective transition from the production of one product to another in a manufacturing unit for various machine-related activities such as machine cleaning, machine re-configuration & re-optimization, and raw materials & parts replacements, among others.
Keeping the lowest Changeover Time enables businesses to adapt to the latest market trends and consumer preferences, and facilitate a smooth supply of products with minimal downtime and reduced cost. Businesses can achieve a lower Changeover Time by adopting various industry-specific and business-specific strategies.
Calculating the Changeover Time
As we’ve already illustrated the changeover time meaning, now let us discuss how to measure the Changeover Time.
The formula for calculating the Changeover Time:
Changeover Time (Average Figure) = Total Time to Changeover Production Lines / No of Changeovers
In the above formula, the Changeover Time represents an average figure. In other words, it is the average timespan for switching from one product to another. The above formula doesn’t take the multitude amount of products or unforeseen circumstances into account.
What are the Steps in the Changeover Process?
There are five steps involved in the changeover process. They are as under:
1. Divide Changeover Process
First things first, divide the Changeover process into various sub-processes and adjust them according to their current sequence. Start each sub-process and analyze the time required for each of these processes. This is important to set a standardized approach throughout the entire process.
2. Record Everything
The second step is to document your observations throughout the entire Changeover process. For example, if you notice any errors or discrepancies, record them. You can also video-record the entire procedure and make an effective use of the checklist.
3. Divide Production-specific Processes
Similar to the first step, we will need to divide the Production-specific processes and then adjust them according to their sequence. Here, you can use a flowchart to analyze and document the order sequence and find areas of improvement through constant coordination with your team members.
4. Time Measurement
The next step is to analyze and document the specific sub-processes in the Changeover process that take more time than others. This is because some sub-processes may take more time than others. For example, testing & validation, calibration, and setup. Setting targets for each sub-process can also help.
5. Gather Feedback
Last but not least, execute the newly transformed Changeover process as one, and monitor it for potential errors and discrepancies. Set up a Feedback system so that your team can record their observations. Furthermore, it’s also important to train your employees to adopt the best practices to reduce the Changeover Time.
What are the Benefits of Reducing the Changeover Time?
An increasing number of businesses across the world are calculating the Changeover Time to rip the following benefits:
1. Lower Production Costs
Reducing the Changeover Time can result in lower idle time of machinery. Reduction in idle time can save fuel and improve production efficiency. Ultimately, the company will make significant savings in production costs without sacrificing product quality.
2. Gain Agility
Reducing the Changeover Time makes the business agile to market competition and customer demands. It gains flexibility and customizability throughout the production process. It can produce smaller quantities of products to meet market trends and fulfill contracts.
3. Optimum Batch Size
Lower changeover reduces the batch size so that the company can cater to the demands of smaller customers, provide personalized offerings to a small target user base, and bring diversity to its product offerings. Moreover, it also reduces the amount of stocks marked as Work-in-progress.
4. Reduce Availability Loss
Other benefits of reducing changeover include a reduction in the availability loss. Availability Losses can occur due to various reasons such as unplanned maintenance, hardware defects, and shortage of raw materials. Reducing the changeover time can lead to a gradual reduction in the availability loss and positively impact your production activity.
5. Process Standardization
Process standardization is one of the benefits of reducing changeover. It can be achieved through Single Minute Exchange of Dies (SMED) involves getting rid of all the non-essential sub-processes (parts) of the changeover process to speed it up and facilitate multiple changeovers without shutting down the machine.
Top 7 Methods to Reduce Changeover Time
A business can reduce the changeover time in various ways. The most popular methods are as under:
1. Checklists Implementation
Businesses can implement the checklist system to standardize the work process and reduce the instances of employees forgetting their crucial tasks. Creating a checklist also benefits in other ways. For example, employees can track their performance, prioritize tasks, and address discrepancies.
2. Machine Layout Optimization
Machine Layout Optimization is a process in material handling in which machines are arranged in such a way that it becomes easier and quicker to transfer materials from one machine to another. It leads to a shorter lead time and a reduction in the setup time of the machinery.
3. Regular Maintenance
Regular repair and maintenance of the machinery is crucial to ensure machines are running at optimal performance and maintain production speed and consistency. It also involves replacing the parts of broken or faulty machinery and setting them to their optimal level.
4. Employee Training
It is possible to reduce changeover time through proper training of the employees and improving their skill sets. Training can help employees follow the best practices while dealing with machines and efficiently perform their tasks. Overall, it can result in lower wastage of time and resources.
5. Adopt SMED Method
The Single Minute Exchange of Die (SMED) method recommends reducing the Lot sizes to lower an organization’s changeover time. This approach can also benefit in another way. When implemented together with an inventory management system, it can lead to better inventory management and efficiency in the handling of Work-in-Progress (WIP) items.
6. Modern Technological Adoption
Adopting modern technology can help manufacturers collect data through Internet of Things (IoT)-based devices, and take benefit of automation. This can result in reduced human errors, accuracy in the work, and elimination of threats to human life and property as in the case of dangerous operations.
7. Focus on Improvement
Another way to reduce the changeover time is to periodically review the processes to find improvement areas and fix discrepancies. The company can encourage innovation and standardization to replace obsolete processes with modern solutions.
Optimizing the Changeover Time Using ERP Software
An ERP Software consolidates data from different departments across the organization and visualizes it through a shared platform. ERP implementation enables businesses to assess production performance, compare target vs actual, and identify discrepancies in the manufacturing process.
Sage X3 is a business-critical solution that provides a robust array of features and meticulously planned modules from maintenance management, supply chain management, inventory management, and order management, to business intelligence. Businesses can benefit from actionable insights, charts, and dashboards. Ultimately, it will result in lower changeover time and increased productivity.
FAQs
1. What is the Definition of Changeover Time?
Changeover Time meaning is the average period it takes between the last production run and the subsequent production run of a different product for various machine-related activities. Modern manufacturing businesses calculate the Changeover Time and take a series of measures to bring it down.
2. What is the Ideal Changeover Time?
There is no ideal changeover time. The changeover time may vary from company to company, and industry to industry. A company should set a changeover time based on the nature of the industry, product specifications, and the technological complexities of the machinery.
3. Which Methodologies Are Commonly Used in Changeover Time?
Multiple methodologies are used in standardizing the changeover time. Some of them include Single-Minute Exchange of Die (SMED), visual management tools, 5S methodology, and setup reduction workshops. A company should choose a methodology that best suits its model of business operations.
4. Does Reducing Changeover Time Lower the Production Costs?
Yes, a reduction in the changeover time is directly linked to reduced downtimes, wastage of material, and manufacturing expenditure. It also increases the machine’s lifespan and lowers its maintenance cost. Overall, the company benefits from lower costs and higher profit margins.
5. What is the Difference Between Changeover Time and Setup Time?
The terms Changeover Time and Setup Time are sometimes used interchangeably. However, they are distinctly different. Setup Time is a subcomponent of the Changeover Time that indicates the time spent in preparing machinery for the new production process. Changeover Time is an all-comprehensive concept that includes everything from cleaning, setting, and starting the machinery.