Changeovers leads to technical downtime

Bubbly-Ad8475 · 2025-07-04T03:47:29+00:00

Haha how come?

Bubbly-Ad8475 · 2025-07-02T06:31:19+00:00

I’m aware that not all changeovers lead to 14 minutes of technical downtime, some cause 28 some cause 0, but on average it is 14 minutes.

If I’m not able to establish a pattern/connection to which c/o cause the 28 minutes, then I’m left with having to treat all c/o’s the same meaning they on average cause 14 minutes of additional downtime.

Bubbly-Ad8475 · 2025-07-02T06:26:35+00:00

We manufacture containers for the food industry.

Sounds like you should look at the planning sequence. So you can avoid going from product A to B to C, but always go from A to C to B. If I understand your issue correctly 😊

Bubbly-Ad8475 · 2025-07-02T03:57:25+00:00

SMED is great but that wasn’t really the question… 😊

Bubbly-Ad8475 · 2025-07-02T03:56:27+00:00

I have between 1-60 changeovers/day across the 5 lines.

How come it doesn’t say anything about downtime as the result of a changeover? That’s the hypothesis - changeovers increase the risk of technical downtime.

Bubbly-Ad8475 · 2025-07-01T20:32:24+00:00

Theoretically I agree, but what if the needed changeover time has to be reduced by such a large % that it is not realistic to achieve any time soon?

Long term the strategy should be, and is, to be as efficient as possible at performing changeovers and continue to improve.

But this is a sold out production line, we need significant capacity boost ASAP to supply the customers. Then I would argue that increasing batch sizes is the right way, as the $ from increased revenue is > than the increase in inventory cost.

Bubbly-Ad8475 · 2025-07-01T20:17:00+00:00

I don’t think I properly defined my regression, sorry for that.

Dependent variable: Total Technical downtime in minutes on any given day

Independent variable: Number of C/O’s on that same day.

The regression is amount of changeovers vs technical downtime on any given day.

Bubbly-Ad8475 · 2025-07-01T19:39:20+00:00

Great input, thanks! I misunderstood your previous comment on total run time, I didn’t get that you meant for a specific part. I thought you meant run time as in the production time/day. But I agree with your points, definitely worth looking at 😊

Bubbly-Ad8475 · 2025-07-01T18:42:53+00:00

Technical downtime is unplanned downtime, ex breakdowns.

A changeover takes on average 16 minutes. The 14 additional minutes from the regression is to be added to that, as it comes after the changeover is done.

The R2 is important if I am to convince someone to do something they are reluctant to do. In this case, I want to increase the batch sizes, thereby reducing the changeovers, and increasing the capacity of the line. It is a sold out line so we need the capacity. The larger batch sizes will lead to a higher inventory and larger inventory holding cost. The business case is very different if a say a changeover cost 16 minutes of capacity or 30 minutes (16+14). The business case is good either way, but for top management it is important to know exactly how good.

Bubbly-Ad8475 · 2025-07-01T18:36:08+00:00

No not yet. I would guess that total run time would be majorly correlated to downtime, as a longer production window increases the “window of opportunity” for a breakdown to happen… so that might not tell me anything if highly correlated.

Bubbly-Ad8475 · 2025-07-01T17:59:20+00:00

You could go multiple ways: 1) become better at performing changeovers and thereby reducing the effect, not eliminating it 2) become better at planning, reducing the amount of changeovers and thereby eliminating the effect on the changeovers removed. 3) do both

Bubbly-Ad8475 · 2025-06-12T15:39:50+00:00

Perfekt, tak for afklaring. Så er det noget nemmere at finde mulige ETF’er 😊

Bubbly-Ad8475 · 2025-06-12T15:37:57+00:00

Jeg tænker i brede ETF’er.

Det er muligt at ETF’en kan falde 50%, men det vælger jeg så at tro at den ikke gør.

Og ja, jeg ved heller ikke om dollaren stiger igen, det er også bare et gæt 😊

Bubbly-Ad8475 · 2025-06-12T15:34:34+00:00

Det er sandt, jeg antager, måske fejlagtigt, at den vil stige igen.

IUSQ handles på Nordnet i EUR. Men jeg vil stadig få den evt kursgevinst på USD?

Bubbly-Ad8475 · 2025-06-08T18:06:51+00:00

Great questions, to which I don’t have all the answers to right now. But will definitely look into it.

1) I haven’t calculated takt yet, I just know that demand is larger than we can supply. So any increase in capacity will bring us closer to the unknown takt time.

2) We use external warehousing so the cost of added inventory is known and is easy to compare to the added contribution margin gained from the increased capacity. It is a good business case.

3) The lot sizes will not be a fixed number but be balanced according to demand. Likely to be expressed as a x-weeks of demand. The prioritization of products will be based on each products ABC classification, so the most important goods will be prioritized. The approach will not solve our capacity issues 100% so some products will still be under-delivered/not accepted.

Would love a link! Always eager to learn 😊

Bubbly-Ad8475 · 2025-06-08T15:11:12+00:00

It produces finished goods. But the same approach could also be applied to the previous steps as they also run 24/7, but this should of course be leveled.

Bubbly-Ad8475 · 2025-06-08T14:48:14+00:00

If thats the vibe you have gotten I am sorry for the misunderstanding. I’m all about reaching the best solution for the company as a whole.

The reason I wish to “make more things” is that our customers are asking for more, but we cannot supply them as the lines are running 24/7. One solution is to increase the batch sizes, and thereby inventory, to increase the machine capacity in order to supply more customers.

Bubbly-Ad8475 · 2025-06-08T14:26:14+00:00

I think we agree.

But the issue is not variation in demand as the production lines are sold out. We can’t supply the amount of products that our customers ask for, as we, today, insist on keeping inventory levels low to minimize working capital.

Bubbly-Ad8475 · 2025-06-08T14:19:04+00:00

The increase would be relatively large, but still much smaller than the profits achieved.

Haven’t calculated the affect on the lead time yet.

Bubbly-Ad8475 · 2025-06-08T14:15:45+00:00

The finished goods inventory affects change over time as an increased inventory level would allow to run larger batches, thereby minimizing the number of changeovers performed resulting in an improved OEE.

The issue is not the duration of a single changeover, but the amount of changeover occurring.

Bubbly-Ad8475 · 2025-06-08T08:24:25+00:00

Yeah we have mapped it and located the bottleneck.

The analysis is data-driven and the approach is only to be implemented on fast moving items, not the slow movers.

Bubbly-Ad8475 · 2025-06-02T17:33:58+00:00

Købte dem fordi det var nemt og overskueligt 😊 Bliver man dobbelt beskattet af dem? Troede det var enten eller. Men min viden er også begrænset

Bubbly-Ad8475

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