Improve Line Changeover Processes to Drive Efficiency and Operator Accountability
Recently, a food manufacturer implemented an eSOP solution with its MES and turned its process improvement team onto the data. The team discovered that the same tasks were taking different amounts of time to perform, depending on the operator shift, which pointed to the need for better training. Additionally, it discovered that moving through the production mix worked better in one direction than others; for example, reducing bottle size was faster and easier than increasing bottle size.
Using the information from electronic work instructions to gain better insight about its changeovers, the company incorporated training and also changed its production to go from largest bottle size to smallest bottle size, reducing the overall time of a line changeover by 35%. The significant improvement resulted in less operator overtime, fewer product rejects, and reduced equipment failures—driving speed and production efficiency.
Profit from Rapid and Reliable Line Changeovers
As some leading companies have begun to discover, the key to speeding up line changeovers without compromising quality relies upon guiding operators through changeover processes with electronic work instructions. The faster that operators can set up machines and recipes correctly, the more efficiently manufacturers can produce many different products on the same line without changeover delays and errors—recovering valuable production time and delivering consistent product quality.
Furthermore, rapid and reliable changeovers enabled by electronic work instructions help manufacturers leverage improved predictability to drive proactive planning of resources, including the reduction of excess inventory. The critical insight manufacturers gain into real-time production helps drive increased agility across the plant—accelerating profit margins for a stronger bottom line.