<h1>Change over</h1>
Guaranteed 30% Reduction in changeover downtime within 1 Week™
“ When an individual’s effort is reduced, the overall change over time will be reduced. As the effort decreases, change over time decreases automatically.” = Ron Heiskell, Founder & CEO, Reduced Effort, Inc.
Reduced Effort, Inc. is a lean manufacturing consulting firm specializing in quick change overs. During a one week Kaizen event we guarantees to reduce the change over downtime of any machine by a minimum of 30%. During this hands-on event operators and managers participate in an innovative 12 step process that will quickly reduce the time and effort of any changeover.
A cultural change begins to take place during the event that will change the way operators think about and perform their work. “When you change the way people look at their work, the way they work changes.” - Ron Heiskell
The cost of packaging line downtime is a significant element of operating costs, and for many manufacturers the major part of downtime is the change over. The chart below shows the hourly cost of downtime by industry:
This above chart was developed from manufacturer surveys and shows the total of direct and indirect costs of downtime, so it includes the cost of power, employees, reduction of products/hour, etc. If we take cost of downtime for food and beverage of $7800/hour, one change over/month could cost $93,600/year, one change over/week costs $390,000/year, and one change over/day costs $1,950,000/year. Therefore if you do one change over/month and reduce this time by 30% you are saving $28,080/year. During these uncertain economic times many customers are ordering fewer quantities with each order, causing manufacturers to do more change overs than in the past. Many manufacturers are doing multiple change overs per day to meet customer demands. For one changeover per day a 30% reduction in time could mean a yearly savings of $585,000.
At Reduced Effort we are delivering these savings, and more, during our 1 week Reduced Effort Changeover (REC) Kaizen Events. If we can’t demonstrate a minimum 30% reduction in changeover time, you pay nothing but our travel expenses. One plant manager stated “In 3 days they cut a 150 min. changeover down to 35 min., and we had been doing it the old way for 25 years.” The following chart shows some examples of actual time reductions
Hourly cost of Downtime by Industry
Sources: ARC Advisory Group, Rockwell Automation, and PMMI
As the number of tasks are reduced (one element of effort), then the time required to perform the series of tasks is automatically reduced.
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Phone: 1-209-814-9198 Email: ron@reducedeffort.com