Changeover kaizen on a high-speed thermoforming line
Food packaging · South Australia
The challenge
Long changeovers on a thermoforming line were forcing large batches, high inventory and late orders for a packaging manufacturer.
Our approach
- Five-day SMED kaizen event with operators and maintenance
- Changeover filmed and analysed step by step
- Tooling carts and quick-release clamps introduced
- Standard changeover procedure created
- 30-60-90 day follow-up audits
Results
What changed.
Changeover time cut from 95 to 28 minutes
Batch sizes halved
Finished goods inventory reduced by 30%
Operators designed most of the improvements
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