How can machine changeover times be reduced by 81%?

Machine configuration

Optimize machine changeover times

Machine changeover times can be really long depending on the complexity of the machine. In many cases, machine changeover times can be reduced by parallelizing the tasks at hand. A changeover process of several hours can therefor be shortend to less than one hour. This type of process requires a digital system since the coordination of many work items at once cannot be handled by a single person.

Long process running times

To reduce machine changeover times the process running times need to be shortened. If work steps are executed in a linear fashion, there is not enough optimization potential. Reducing a changeover process by a few seconds in each step only yields single digit improvements. A step change can not be achieved with making a barcode scan become 2 seconds faster.

Unnecessary wait times before tasks can start

Between a worker finishing a work procedure and a technician arriving to perform a machine changeover, there are usually several minutes of time being wasted. Maintenance technicians are not alerted ahead of time but only after a process has come to finish. In order to reduce wait times between processes, it is necessary to implement a system that can look ahead on upcoming tasks and schedules them accordingly.

Paper documentation creating unnecessary roundtrips

Often paper documentation for changeover procedures is the norm on the shopfloor. Since a paper process is very static, technicians often are unable to avoid roundtrips to fetch spare parts or tools required for the job. A paperless maintenance procedure will adapt to the specifics of a changeover process and alert the technician ahead of time to fetch the correct tools and spare parts.

Our Solution.

Implementing a digital machine changeover process is a standard feature of the WORKERBASE platform. The guideline for shortening machine changeover times is based on three fundamental steps:

Process parallelization

Each step in the original workflow needs to analysed if it can be executed in parallel versus in a serial fashio

Digital coordination

when process steps run in parallel, humans are unable to coordinate work. The WORKERBASE platform manages parallel task execution in a simple rules based system.

Avoid roundtrips

a last optimization step is to avoid roundtrips by equipping the worker with all required information right away

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Your Results!

A parallel execution of workflow steps can unlock enormous savings potential in a direct and indirect way. Quite often, the indirect savings offer the biggest potential.

Reduction of changeover procedure running times by up to 81%.

Avoidance of worker roundtrips across the shopfloor

Flexibility on worksteps and immediate reflection of machine updates

Indirect savings such as warehouse stock can easily be in the order of magnitude of millions of Euros

How WORKERBASE can help you

Our commissioning system supports task parallelization out of the box. If you would like to evaluate how your workflows can be digitally delinearized, then please get in touch with us.

I am especially interested in the following use cases: