5s increase productivity, safety, and culture through the implementation of the 5S System. If you seek to optimize workplace efficiency, boost productivity, and ensure safety, while also improving your work environment, the 5S Japanese System could be the ideal solution for you.
Every minute your machine sits idle during changeover is money walking out the door.
You know the frustration. Your production line stops for what should be a “quick” changeover. Two hours later, you’re still waiting. Meanwhile, orders pile up, customers get impatient, and your competitors are shipping products while you’re still fumbling with setup.
If this sounds familiar, you’re not alone. But you don’t have to stay stuck.
Most plant managers focus on the big problems—equipment breakdowns, quality issues, material shortages. But there’s a silent profit killer that’s probably costing you more than all of these combined: inefficient changeovers.
Think about your last changeover:
Now multiply that by every changeover you do.
The numbers are staggering, aren’t they?
Here’s the brutal truth: Most manufacturers lose between $500,000 and $2 million annually to inefficient changeovers.
Your industry faces unique changeover challenges that other manufacturers don’t understand:
Smart manufacturers in your industry have discovered SMED (Single Minute Exchange of Die)—the systematic approach to reducing changeover times from hours to minutes.
SMED isn’t magic—it’s methodology. Developed at Toyota and perfected in manufacturing plants worldwide, it systematically eliminates changeover waste through four proven steps:
The result? Changeovers that used to take 4-6 hours now take 15-30 minutes. Quality improves. Stress decreases. Profits soar.
Virtually all companies that choose to implement it & will get started with the best of intentions. Over time, organizations often experience a decline in focus and adherence to the 5S principles, leading to a neglect of the system. Before implementing 5S, it is crucial for companies to understand the common reasons for its failure. By doing so, they can proactively address these issues and increase the chances of successful implementation.
Before: 4-hour mold changes, limited to long production runs, losing small-batch business After: 22-minute changeovers, 300% increase in product variety, $1.2M additional annual revenue "We went from dreading changeovers to embracing them. Now we can say 'yes' to orders we used to turn away."
Before: 3-hour format changes, FDA compliance concerns, limited flexibility After: 18-minute changeovers, full regulatory compliance, 400% improvement in OTIF delivery "We proved you can be fast AND compliant. Our competitors are scrambling to catch up."
Before: 6-hour line cleaning between products, massive inventory requirements After: 45-minute transitions, 60% inventory reduction, improved cash flow by $800K "Our customers noticed immediately. Lead times went from weeks to days."
SMED isn’t magic—it’s methodology. Developed at Toyota and perfected in manufacturing plants worldwide, it systematically eliminates changeover waste through four proven steps:
The result? Changeovers that used to take 4-6 hours now take 15-30 minutes. Quality improves. Stress decreases. Profits soar.
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