Product Change Over Time

During the design phase of your manufacturing plant, did the subject of product change over enter into the discussion. Was it reviewed in detail looking at every aspect of the plant.

Rarely does this subject get the time it deserves the supplier says the plant is easy to clean and the customer accepts this.

If we have some potentially explosive material, we have an expert review. We eliminate obvious and sometimes not obvious areas of potential problems in the design phase. Then engineering solutions are derived to match the requirements of the safety review.

Why is Change Over Time Important

In manufacturing, changeover time refers to the time it takes to switch a production line or machine from producing one product to another. Reducing this time is crucial for several reasons:

1. Increased Productivity

• Shorter changeover times mean less downtime, allowing for more production within the same time frame.

2. Flexibility and Responsiveness

• It enables manufacturers to quickly respond to changes in customer demand or market trends, supporting just-in-time (JIT) and lean manufacturing systems.

3. Cost Reduction

• Less downtime leads to lower labour and operational costs. It also reduces the need for large inventories, minimizing storage costs and waste.

4. Improved Equipment Utilization

• Machines spend more time producing and less time idle, leading to better return on investment (ROI) for equipment.

5. Higher Quality and Consistency

• Efficient changeovers often involve standardized procedures, which reduce the chance of human error and defects during product transitions.

6. Smaller Batch Sizes

• With faster changeovers, smaller batches become economically viable, allowing for greater product variety and customization.

With a Food, Chemicals and Pharmaceuticals going through a number of stages either in a liquid phase or powder phase it is not always possible to move the issue to what we call an External Step as in SMED (Single-Minute Exchange of Dies) but we have to find a way to remove what will cause a delayed change over.

Our issues are generally around cross contamination, this can be caused by:

• Product hang up in various parts of the plant
• It can be difficult or impossible places to clean
• Badly designed transfer lines
• Lack of access points on the plant and lines.
• Poor choice of equipment not designed for ease of cleaning, pumps, transfer systems, dosing systems and weigh systems.

This list could and should go on. At My Manufacturing Plant we work with you at the early design phase. We review all raw materials:

• Are they a potential contaminator.
• Are they standard across the range.

Then we review the plant process flow:

• Where best for the contaminators to enter the manufacturing system.
• Post the entry of any contaminators what decontamination options do we have:
  • Washing out with liquid or powder.
  • All parts must be accessible, access doors, removable sections.
  • Removal in design of product hang up points.
  • Using a polished finish to allow ease of cleaning
  • Avoiding long interconnections between plant equipment. Weighing to mixing vessel to packing.

These are only a few of the steps needed along with all the safety requirements to provide you a safe design with the in-built features to allow fast change over times.

Contact us via www.mymanufacturingplant.com or sales@mymanufacturingplant.com

Let’s design a plant together that provides Safety and Efficiency as Standard.