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Changeover is the process of reconfiguring a machine by changing molds, clamping joints, etc., during which the machine switches from producing one type of product or part to producing another type. Changeover is one type of forced downtime from the equipment downtime classification that affects overall production productivity.

What Is Changeover Time?

Changeover time is the amount of time a tool is replaced or reset. It is equal to the period that passes between the last completed production of the previous type of product and the first suitable product of the new type.

For effective enterprise asset management, it is important to create a production schedule, taking into account the time of changeover.

What Is Changeover Used for?

During the changeover, for example, the tool used during production may be replaced due to its wear or transition to a new type of product. Another option is the transition of the enterprise from the production of one type of product to another, which requires a change of equipment.

What Actions Occur During the Changeover?

During the changeover procedure, employees perform the following actions:

  1. The previous tool is dismantled. This includes removing fittings, clips, dies, and fasteners; machine and conveyor cleaning; dismantling of parts, tools, and everything related to the completed batch of the previous type of product.
  2. A new type of equipment is being installed. At this stage, the new equipment, dies, clamps, and fasteners are not yet set up.
  3. Adjust the machine according to the technical requirements, adjusting the equipment, fasteners, stamps, and clamps.
  4. Make test runs and create a test product. At this stage, the permissions are checked, if necessary, the machine is stopped, adjusted, and a new type of product is tried again. Finished products are not produced.

Changeover Time in OEE

Changeover time as a planned stoppage is used in the OEE analysis of production. The fact is that this time could be used to create products, but for obvious reasons, it is impossible to do this, as well as the time for planned preventive maintenance. At the same time, it is impossible to avoid the changeover, if there is such a need at the enterprise. Although in most cases, its duration can be significantly reduced by applying SMED (Single-Minute Exchange of Die) technology.