manufacturing Manufacturing is the creation or production of goods with the help of equipment, labor, machines, tools, and chemical or biological processing or formulation. It is the essence of secondary sector of the economy. The term may refer to ...

, changeover is the

process A process is a series or set of activities that interact to produce a result; it may occur once-only or be recurrent or periodic. Things called a process include: Business and management *Business process, activities that produce a specific se ...

of converting a line or machine from running one product to another. Changeover times can last from a few minutes to as much as several weeks in the case of

automobile A car or automobile is a motor vehicle with wheels. Most definitions of ''cars'' say that they run primarily on roads, seat one to eight people, have four wheels, and mainly transport people instead of goods. The year 1886 is regarde ...

manufacturers retooling for new models. Reducing changeover times became a popular way to reduce waste in Lean manufacturing after Taiichi Ohno and Shingo Shigeo popularized the SMED (Single Minute Die Exchange) method in the, now famous, Toyota Production System (TPS). The terms ''set-up'' and ''changeover'' are sometimes used interchangeably however this usage is incorrect. Set-up is only one component of changeover. Example: A soft drink bottler may run 16oz glass bottles one day, perform a changeover on the line and then run 20oz plastic bottles the next day.

The 3 Ups

Changeover can be divided into the 3 Ups:

Clean-up

''Clean-up

product Product may refer to: Business * Product (business), an item that serves as a solution to a specific consumer problem. * Product (project management), a deliverable or set of deliverables that contribute to a business solution Mathematics * Produ ...

, materials and

component Circuit Component may refer to: •Are devices that perform functions when they are connected in a circuit. In engineering, science, and technology Generic systems * System components, an entity with discrete structure, such as an assem ...

s from the line. It may range from minor, if only the

label A label (as distinct from signage) is a piece of paper, plastic film, cloth, metal, or other material affixed to a container or product, on which is written or printed information or symbols about the product or item. Information printed ...

of a package is being changed (for example from an

English English usually refers to: * English language * English people English may also refer to: Peoples, culture, and language * ''English'', an adjective for something of, from, or related to England ** English national ide ...

to a

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label) to major, requiring complete disassembly of the equipment, cleaning and sterilizing of the line components in the case of an injectable pharmaceutical product.

Set-up

''Set-up'' is the process of actually converting the equipment. This may be achieved by adjusting the equipment to correspond to the next product or by changing non-adjustable "change parts" to accommodate the product. Typically it will be a combination of both.

Start-up

''Start-up'' is the time spent fine tuning the equipment after it has been restarted. It is characterized by frequent stoppages, jams, quality rejects and other problems. It is generally caused by variability in the clean-up and set-up or by variability in the product or its components.

The 3 Ups

Clean-up

Set-up

Start-up

See also