In manufacturing, every minute counts. And when it comes to changeover time, the period spent switching a machine or production line from one task or product to another, those minutes add up fast. Long changeovers reduce production capacity, inflate costs, and can leave customer orders hanging.
So, how do manufacturers take back control of their schedules and squeeze more productivity out of each shift? The answer starts with smarter strategies on the floor and ends with a modern ERP system like Infor SyteLine to tie it all together.
First, What’s Slowing You Down?
Before you can fix it, you have to see it clearly. Changeover inefficiencies are often a mix of:
- Manual processes that rely on tribal knowledge instead of standardized procedures
- Lack of visibility into scheduling, parts availability, or maintenance status
- Inconsistent setup methods that vary from operator to operator
- Missing or misplaced tools and materials at the start of a changeover
- Inefficient sequencing of jobs that increase time between runs
These aren’t one-off issues. They’re systemic. That means solving them requires both lean manufacturing tactics and the right digital infrastructure.
Proven Strategies to Reduce Changeover Time
Manufacturers that tackle changeover time successfully tend to follow a few core approaches. Here are some of the most effective:
1. SMED (Single-Minute Exchange of Die) Principles
Originally developed in the automotive industry, SMED focuses on reducing changeover times to single digits (less than 10 minutes).
- Separate internal and external tasks. Internal tasks require the machine to be stopped. External tasks can be done while it’s running. The goal is to move as many tasks as possible to the external category.
- Streamline internal tasks. Improve how tasks are performed using better tools, jigs, and standard work.
- Standardize procedures. Create repeatable, step-by-step setup guides to minimize variation between operators.
2. Pre-Staging Materials and Tools
Waiting on a tool, part, or documentation during a changeover is a surefire way to kill productivity. Pre-kitting tools and materials for the next job and staging them at the machine can shave minutes or even hours off setup time.
3. Visual Management and Checklists
Operators shouldn’t have to rely on memory or guesswork. Visual setup guides, photos, color-coded labels, and digital checklists keep everyone on the same page and help prevent rework or errors during changeover.
4. Better Scheduling
Job sequencing matters. If you’re constantly jumping between vastly different products or materials, you’re making life harder than it needs to be. Grouping similar jobs can reduce tool changes, material swaps, and adjustments.
5. Cross-Training Operators
Skilled operators who can handle changeovers confidently across multiple machines reduce downtime and create more scheduling flexibility.
Where ERP Makes All the Difference
All of those strategies are easier said than done unless you’ve got a smart system behind the scenes. This is where an ERP system like Infor SyteLine, backed by Godlan’s decades of manufacturing consulting experience, becomes a game-changer.
Here’s how Infor SyteLine supports lean, fast changeovers:
Real-Time Scheduling and Visibility
- Access production schedules and job priorities from anywhere on the floor
- React quickly to order changes or urgent jobs without guesswork
- See upcoming changeovers and start preparing materials in advance
Standardized Work Instructions
- Build and store digital setup instructions within the ERP system
- Attach visual work guides to job travelers
- Eliminate variability between operators or shifts
Material and Tool Readiness
- Automatically reserve tools and materials for upcoming jobs
- Trigger alerts if anything is missing or not at the correct station
- Connect with inventory systems and barcode scanning for accurate, real-time updates
Job Sequencing Intelligence
- Optimize production runs based on changeover impact, not just due dates
- Group similar jobs to minimize tool swaps and machine resets
- Simulate different sequences and see the effect on changeover time and delivery
Integration with IoT and Shop Floor Data
Through Prophecy IoT®, also from Godlan, you can monitor machines in real time, collect data on actual changeover durations, and spot patterns that drive continuous improvement. Are setups taking longer on a specific machine? Are certain shifts consistently faster? Data makes those insights obvious and actionable.
Don’t Let Changeovers Drain Your Bottom Line
If changeovers are slowing you down, you’re not alone. But with the right mix of lean thinking and smart systems, it’s absolutely possible to turn changeovers into a strength instead of a setback.
At Godlan, we’ve helped manufacturers reduce waste, boost throughput, and transform how they work for over 40 years. We implement solutions like Infor SyteLine ERP and Prophecy IoT to bring clarity and control to even the most complex shop floors.
Schedule a consultation with Godlan today and find out how you can reduce changeover time and increase profitability, without adding headcount or hours.
