The Challenge
A yarn manufacturing division was losing significant production capacity to slow and inconsistent changeovers between product runs. Operators had developed their own personal routines over time, and the variation between individuals and across shifts was creating unpredictable machine downtime that made production planning unreliable.
Delivery delays and quality inconsistencies were the visible symptoms of a process that had never been standardized.
The Approach
A detailed diagnostic mapped every step in the changeover workflow, identifying specific sources of delay in material readiness, operator sequencing, equipment preparation, and communication handovers. A redesigned changeover method was developed and implemented:
- Standard work and parallel tasking principles were applied to ensure preparation steps were completed before machines stopped wherever possible
- The sequence of actions was made consistent across every operator and every shift
- Visual guides were deployed at the point of work to clarify expectations and make the standard visible
- Operators received targeted skill training on the new method
- Supervisors were equipped with real-time performance tracking tools to identify variation early and reinforce discipline consistently
The Outcome
Machine downtime decreased by more than 20 percent, unlocking production capacity valued at approximately $145,000 CAD per year. On-time delivery improved by 12 percent and quality consistency increased as operators adopted a unified standard.
The initiative reduced fatigue and frustration among staff and gave leadership clear, reliable visibility into changeover performance for the first time.