How To Reduce Changeover Time

Purpose

Help teams identify, measure, and reduce the time it takes to change from one job, part, or setup to another — using data captured in Caddis to drive structured improvements and accountability.

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�“Setup times dropped from 14 minutes to 9 just by focusing weekly and assigning ownership.”

‍— Manufacturing Engineer, Aluminum Manufacturer (LeClaire Meeting)

Outcomes

• Shorter, more consistent changeover times
• Clear accountability for changeover execution
• Data-driven improvement process for setup activities
• Increased machine availability and throughput

Tools You’ll Use in Caddis:

• Run and downtime history for each machine
• Tags (e.g. Part Number, Job Number, Operator)
• Downtime thresholds (to flag excessive setups)
• Notes on excessive downtime events
• Weekly reports comparing shift/setup performance

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Timeline:

4–6 weeks initial improvement sprint, then ongoing weekly follow-up

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Who’s Involved:

• Caddis Champion
  
  • Tracks setup times and tags active runs
• Operators
  
  • Execute changeovers and follow checklists
• Maintenance
  
  • Support for tool or fixture issues
• Production Manager
  
  • Reviews changeover metrics weekly
• Engineering
  
  • Supports fixture/tooling or redesigns

Step-by-Step Execution

Step 1: Tag All Active Runs by Job or Part

Make sure every active run in Caddis includes tags like:

• Part Number
• Job Number
• Operator Name

This allows you to compare average setup times by:

• Operator
• Job type
• Shift
• Part Number

📌 Caddis tags are applied at the start of an active run, grouped by category. Use these to build production context.

Step 2: Identify Setup Events Through Downtime Analysis

Use Caddis to locate excessive downtime periods between tagged runs:

• Look for repeat setups that exceed your target time (e.g., >10 min)
• Cross-reference notes or operator comments for cause

Use this to:

• Quantify average and worst-case setup time per job
• Identify jobs or operators with high variation

Step 3: Create a Changeover Checklist

Use 5 Why’s to identify barriers in long setups:

• Why did this setup take so long?
• Why wasn’t tooling ready?
• Why wasn’t the fixture preloaded?

Design a standard checklist for pre-setup and execution:

• Confirm tool/fixture staged
• Material ready
• Operator trained
• First article inspection expected time

🧠 Use root cause findings to define new checklist items.

Step 4: Assign Setup Ownership and Start Weekly Standups

Each high-variation setup should have an owner:

• Could be the lead operator or area supervisor

Start a 30-minute weekly review meeting:

‍Attendees: Operators, Caddis Champion, Production Lead

Agenda:

1. Review average and longest setup times by job
2. Investigate any excessive events
3. Identify one improvement for the next week
4. Validate checklist use and prep actions

🔁 Build weekly momentum and celebrate wins.

Step 5: Add a PM if the Setup Delay Was Mechanical

If a root cause is related to:

• Tooling wear or fixture misalignment
• Dirty machine bases
• Sensor or calibration drift

Use your 5 Why’s worksheet to:

• Identify the root cause
• Build a PM that prevents recurrence

🛠 Example: "Fixture bolts loose" → PM every 60 hours: Inspect bolt torque

Metrics to Track

Common Challenges (and Solutions)

✅ What Success Looks Like:

• Setups become routine and repeatable
• Less machine downtime between jobs
• Setup time is known, measured, and improved
• Preventive actions are tied to mechanical delays

📝 5 Why’s Root Cause Worksheet (Printable)

Use this worksheet during changeover investigations to build better prep and PMs.

Setup Issue Description:

Why #1: Why was this setup delayed?

Why #2: Why wasn’t the material/tooling ready?

Why #3: Why was that step missed?

Why #4: Why wasn’t someone assigned to check it?

Why #5: Why isn’t that built into our process?

Root Cause Statement:

Proposed Fix (Checklist or PM):

Owner: ___________________ Due Date: ________________

Follow-Up Notes:

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