Reducing downtime during changeover is a goal that any cost-conscious manufacturer would pursue. The reality of today’s market is there’s a great variety of products and sizes to meet consumer demands. It’s becoming more common for retailers to set specific requirements about the material and packing methods used, such as shelf-ready packaging. That means the responsibility is on manufacturers to accommodate these requirements with shorter runs and an increased number of changeovers.
With changeovers, circumstances can arise that cause downtime. When mechanical failure or human error add even more minutes to downtime, it can cause problems like missed deadlines, increased waste and profit losses.
Changeovers can’t be avoided, but their effects on downtime can be minimized through workforce training and mechanical solutions.
All too often, the manufacturers encounter a limited talent pool of experienced machine operators who can execute a quick, successful changeover.
Talk to any two operators, and they’ll have different opinions on which machine settings are best. Establishing standard settings raises confidence that the machine will work after a changeover. Improving repeatability results in less time spent adjusting and tweaking the settings, along with eliminating reliance on personal preferences that lead to inconsistent outcomes.
Coping with components
The number of parts and tools needed to execute a changeover can lead to confusion, variability and error. That only increases the odds of breakage and faults.
While an Operations Manager would focus on smarter procedures to pare back the minutes of downtime, mechanical solutions can help them achieve their goals with greater consistency. Whether that means updating existing secondary packaging machinery or investing in new, automated equipment, here are a few considerations.
When there’s a changeover, each part has a number of change points that link and lock to the machine. More change points mean more opportunity for line-halting breakage and machine failure. Reducing change points to one single point along with streamlining the number of components results in a faster, faultless changeover.
Because of scheduling demands, a machine operator can be rotating through different machines through the work week, or an operator may only complete one changeover a week. When it’s time for a changeover, shift managers are doing battle with the clock and a lengthy learning curve. The design of the machine parts can eliminate some of these headaches around changeovers. Clearly marked change parts for size and function, along with a clear and logical sequence, shortens time needed on changeovers, reduces human error that leads to faults, and allows managers to make better use of their team.
When it comes to changeovers, waste comes with the territory, due to the cleanout and priming processes. Simple improvements to the machine design such as a shorter conveyor reduces the amount of product needed for priming. These improvements provide waste savings when it’s time to transition to a changeover. The ability to reduce waste brings more precision into planning.
Ready to optimize your production line with secondary packaging machines that support your team’s ability to execute quick, precise, easy-to-implement changeovers? Douglas’s SmartSelectTM Automatic Changeover is just one of the features available to help you do just that. Fast, repeatable changeovers in less than five minutes, recipe-driven for repeatability and the flexibility to generate product-specific recipes. Get in touch with a Douglas team member now to learn more about how our line of innovative secondary packaging solutions can be completely customized to your unique needs.
Necessary cookies are absolutely essential for the website to function properly. These cookies ensure basic functionalities and security features of the website, anonymously.
This cookie, set by Cloudflare, is used to support Cloudflare Bot Management.
HubSpot sets this cookie to keep track of sessions and to determine if HubSpot should increment the session number and timestamps in the __hstc cookie.
This cookie is set by Hubspot whenever it changes the session cookie. The __hssrc cookie set to 1 indicates that the user has restarted the browser, and if the cookie does not exist, it is assumed to be a new session.
Google Recaptcha service sets this cookie to identify bots to protect the website against malicious spam attacks.
This cookie is set by GDPR Cookie Consent plugin. The cookie is used to store the user consent for the cookies in the category "Analytics".
The cookie is set by GDPR cookie consent to record the user consent for the cookies in the category "Functional".
This cookie is set by GDPR Cookie Consent plugin. The cookie is used to store the user consent for the cookies in the category "Other.
Set by the GDPR Cookie Consent plugin, this cookie records the user consent for the cookies in the "Advertisement" category.
This cookie is set by GDPR Cookie Consent plugin. The cookies is used to store the user consent for the cookies in the category "Necessary".
This cookie is set by GDPR Cookie Consent plugin. The cookie is used to store the user consent for the cookies in the category "Performance".
CookieYes sets this cookie to record the default button state of the corresponding category and the status of CCPA. It works only in coordination with the primary cookie.
The website's WordPress theme uses this cookie. It allows the website owner to implement or change the website's content in real-time.
New Relic uses this cookie to store a session identifier so that New Relic can monitor session counts for an application.
Analytical cookies are used to understand how visitors interact with the website. These cookies help provide information on metrics the number of visitors, bounce rate, traffic source, etc.
Hubspot set this main cookie for tracking visitors. It contains the domain, initial timestamp (first visit), last timestamp (last visit), current timestamp (this visit), and session number (increments for each subsequent session).
Facebook sets this cookie to display advertisements when either on Facebook or on a digital platform powered by Facebook advertising after visiting the website.
1 year 1 month 4 days
Google Analytics sets this cookie to calculate visitor, session and campaign data and track site usage for the site's analytics report. The cookie stores information anonymously and assigns a randomly generated number to recognise unique visitors.
1 year 1 month 4 days
Google Analytics sets this cookie to store and count page views.
Google Analytics sets this cookie for user behaviour tracking.
Google Tag Manager sets the cookie to experiment advertisement efficiency of websites using their services.
Google sets this cookie to allow the use of Google Analytics service for anonymous visitor tracking on the website. Google Analytics is used to compile reports and improve the site.
Google Analytics sets this cookie to store information on how visitors use a website while also creating an analytics report of the website's performance. Some of the collected data includes the number of visitors, their source, and the pages they visit anonymously.
Linkedin set this cookie to store information about the time a sync took place with the lms_analytics cookie.
1 year 1 month 4 days
BrightEdge sets this cookie to enable data aggregation, analysis and report creation to assess marketing effectiveness and provide solutions for SEO, SEM and website performance.
This cookie is set by the Provider CallRail. This cookie is used for storing an unique identifier for a user browser session. It is used for tracking the number of phone calls generate from the website.
YouTube sets this cookie via embedded YouTube videos and registers anonymous statistical data.
HubSpot sets this cookie to keep track of the visitors to the website. This cookie is passed to HubSpot on form submission and used when deduplicating contacts.
An Adobe Analytics cookie that uses a unique visitor ID time/date stamp to identify a unique vistor to the website.