This document summarizes a process improvement project to standardize changeovers on a pickles production line. The original changeover process took too long, required excessive tuning, and resulted in high waste and overtime costs. The new standardized changeover process reduced changeover times from 90 minutes to 70 minutes and 60 minutes to 45 minutes. It requires little to no tuning and has significantly reduced setup time, waste, and overtime costs, saving over £37,000 per year. Morale has also improved as changeovers are now quicker and more consistent.

1. Success Bulletin
Name (s) Finish DateStart Date
‘Before’ picture (sketch/photo):
‘After’ picture (sketch/photo):
Problem Description: Solution Description:
Loss (Reasons for Improvement): Benefits (Results Achieved):
S Q P C D M Circle relevant
Ref No
‘Continuously Challenge the Status Quo’
Dept./ Function:
LES FRITH, ATTILLA SZABO,NEIL
HARDINGHAM,ANDY GILLARD
SUTR A3 25/05/2015 30/01/2016
PICKLES LINE 5
MULTIPLE CHANGEOVERS TIME CONSUMING VARYING RAMP UP TIMES AND FREQUENT TUNING TO
GET TO EXPECTED RUN RATES EXCESSIVE WASTE DURING FINE TUNING AND RAMP UP'S. 729 GBP
PER WEEK OVERTIME AVOIDANCE (1 HR PER WEEK = 243 GBP PER HR O/T avoidance based on a ten
man crew having to work 3 hours O/T on line 5 @ 1.5 HRs per hour off shift.) Total annual avoidance of £37,179.
NUMEROUS RUNS ON LINE 5 WITH MULTIPLE CHANGEOVERS
MORALE IS LOW AS CHANGEOVERS ARE TIME CONSUMING
WITH VARYING RAMP UP TIMES AND FREQUENT TUNING
REQUIRED TO GET TO EXPECTED RUN TIMES/OUTPUTS WITH
EXCESSIVE WASTE DURING FINE TUNING AND RAMP UP'S.
SET UP TIME AVERAGES 9 HOURS PER WEEK.
STANDARDISED CHANGEOVERS FOR LINE 5 PRODUCTS WITH
EASY, QUICK AND SAFE PROCESSES WITH LITTLE OR NO
TUNING REQUIRED ALLOWING RAMP UP TIME AND WASTE TO
BE REDUCED, EMBRACING SMALLER BATCH RUNS WITH NEW
STANDARDISED PROCESS. REDUCE SET UP TIME FROM 9 -6
HOURS PER WEEK.
STANDARDISED CHANGEOVERS FOR LINE 5 PRODUCTS,
LITTLE OR NO TUNING REQUIRED C/O TIME REDUCED 90
MINS TO 70 MINS & FROM 60 MINS to 45 MINS. EMBRACING
SMALLER BATCH RUNS WITH NEW STANDARDISED
PROCESS. REDUCED SET UP TIME FROM AVERAGE 9 HOURS
PER WEEK TO SIX HOURS PER WEEK, A REDUCTION OF 33%
= 3 HOURS PER WEEK SOFT SAVING OF £37,179 p.a.
High Variation C/O’s
Reduced Variation C/O
Change over times varied and non-standardised Consistent & Standardised Change over times visible