Study
Changeover and start-up loss review
Focused work on first-hour output after a change of product, pack, or tool — where many halls lose a quiet third of a shift.
Who it is for
Plants with frequent SKU or pack changes whose logs bury start-up under a generic ‘set-up’ code.
What you take away
A picture of first-hour volume versus the rest of the run, and a short list of waits that sit between ‘ready’ and ‘at rate’.
Scope
Agreed changeovers on named lines during a visit window, plus the matching log extracts.
Included
- Observation of at least two changeovers of the same family where the diary allows
- Charts of first-hour versus later-hour output
- Notes on waits for quality release, packing materials, or the next crew
Not included
- Writing a full SMED programme as a training course
- Buying jigs or tooling
Who attends
Content Crafthub study lead.
How it runs
Diary of planned changes, visit, charts, briefing with production.
Time
Two to three days on site, depending on the changeover calendar.
Where
Your plant, timed to real changeovers — not a classroom exercise.
What to prepare
A week’s changeover plan and who signs the line back to production.
Limits
If a changeover is cancelled, we observe the running line or reschedule that portion.
Fees
Quoted from the day rate; cancelled changeovers are discussed before extra days are billed. See the fees page for day rates and starting figures.
Next step
Share the next fortnight of planned changes.