Views: 0 Author: Wendy Liu Publish Time: 2026-05-27 Origin: Jewshin
Table of Contents
If you run more than five product SKUs on a single packaging line, changeover time is probably one of your biggest hidden production costs.
Not because each individual changeover takes that long. But because it happens constantly — sometimes multiple times per shift — and the cumulative effect on annual production capacity is enormous.
Consider a typical mid-size manufacturer running 20 SKUs across two shifts:
Average changeover time: 45 minutes
Changeovers per day: 6
Total daily changeover time: 4.5 hours
Annual changeover time (250 days): 1,125 hours
At a line output value of $3,000/hour: $3,375,000 in lost production capacity per year
That's not a maintenance problem. That's a strategic problem — and it's one that the right machine design, the right process, and the right operating discipline can largely eliminate.
This guide gives you the complete framework: the methodology, the machine features to look for, the process steps to implement, and the realistic time benchmarks you should be hitting on each machine type.
A changeover (also called a format change or size change) is the process of reconfiguring a packaging machine — or an entire packaging line — to run a different product SKU.
Depending on what changes between SKUs, a changeover may involve:
What Changes | Changeover Tasks Required |
Product dimensions only (same format, different size) | Adjust guides, change bag dimensions, update parameters |
Packaging format (e.g., flow wrap → shrink wrap) | Major reconfiguration; may require different machine |
Film type or width | Film roll change, tension adjustment, temperature recalibration |
Seal type (heat seal → self-adhesive) | Tooling change, parameter update |
Count per pack (e.g., 5 cards → 10 cards) | Feeder parameter update, bag dimension adjustment |
Label design (same container, new label) | Label roll change, sensor calibration |
The goal of changeover optimization is to reduce the time between last good pack of SKU A and first good pack of SKU B — without compromising quality on either side.
SMED — Single-Minute Exchange of Die — is the industrial engineering methodology developed by Shigeo Shingo at Toyota that transformed manufacturing changeover times worldwide. Despite the name, the goal isn't literally one minute — it's to reduce changeover time to single-digit minutes wherever possible.
The SMED framework has three core principles:
Internal activities can only be done while the machine is stopped.External activities can be done while the machine is still running the previous SKU.
Most manufacturers treat everything as internal — they stop the machine, then start thinking about what they need for the next run. SMED reverses this: prepare everything for the next run before stopping the machine.
Examples of activities that should be external (done before stopping):
Retrieve the next film roll and stage it at the machine
Print and stage the parameter record sheet for the next SKU
Prepare and count spare parts or tooling needed
Recall the next SKU's parameters on the HMI (if possible while running)
Brief the operator on any special requirements for the next SKU
Stage the next product batch at the infeed
Rule of thumb: If you can do it before stopping the machine, it should never be done after stopping.
Some tasks that currently require the machine to be stopped can be redesigned — through better tooling, better machine design, or better process — to be done while running.
Example: On an older machine, film roll changes require stopping because the film path must be re-threaded from scratch. On a modern machine with a film splicing table and pre-loaded standby roll, the operator can prepare the new roll while the machine runs and splice it in with a 30-second stop.
For activities that genuinely require the machine to be stopped, eliminate every source of delay:
Replace bolts and tools with hand-adjustable knobs and levers
Replace measurement-based adjustments with pre-set position stops
Replace manual parameter entry with stored parameter recall
Replace verbal instructions with visual standard work sheets posted at the machine
Changeover speed is not just a process problem — it's a machine design problem. The right machine features make fast changeover possible. The wrong features make it structurally impossible, regardless of how disciplined your operators are.
When evaluating packaging machines for multi-SKU operations, these four design features are non-negotiable:
Every mechanical adjustment that requires a wrench, screwdriver, or Allen key adds time and introduces the risk of incorrect torque, lost tools, and operator variation.
What to look for:
Hand-adjustable knobs for guide width, height, and position
Quick-release levers for format parts (side guides, infeed rails, discharge guides)
Graduated scales and position indicators on all adjustable components
Color-coded adjustment points that match the parameter record sheet
What to avoid:
Bolted guide rails that require tools to reposition
Unlabeled adjustment points with no position reference
Adjustments buried inside machine guards that require guard removal
JEWSHIN design standard: All JEWSHIN bagging machines (JX-L300, JX30-35, JX35-50) and flow wrappers feature tool-free size changeover as standard. Guide adjustments use hand-knobs with graduated scales. No tools are required for standard format changes.
On a modern servo-driven packaging machine, most of the "adjustment" work is actually parameter adjustment — bag length, seal temperature, speed, tension, timing. If these parameters must be re-entered manually for every changeover, you're adding 5–15 minutes of setup time and introducing operator error risk.
What to look for:
HMI (touchscreen) with named product recipe storage
Minimum 40 product recipes storable
One-touch recipe recall by product name or SKU code
USB export/import for parameter backup and transfer
Parameter record sheet template (printed reference for each SKU)
What to avoid:
Machines with no parameter storage (operators re-enter values from memory or handwritten notes)
Systems that store parameters by number only (no product name — operators can't identify the right recipe)
No USB backup capability (parameter loss during power failure requires full re-setup)
JEWSHIN HMI standard: The ZS-350 and all JEWSHIN servo packaging machines store up to 40 named product recipes. Operators recall the next SKU's parameters with a single touchscreen selection. Parameter backup to USB is standard on all models.
On older mechanical packaging machines, bag length is set by physically adjusting a cam or chain sprocket — a process that can take 20–30 minutes and requires the machine to be stopped. On servo-driven machines, bag length is a digital parameter — change the number on the touchscreen and the machine adjusts instantly.
What to look for:
Servo motor control for film pull, bag length, and seal position
Digital bag length setting (no mechanical cam adjustment)
Automatic film tension adjustment (no manual tension roller repositioning)
Servo-controlled cross-seal timing (adjusts automatically with bag length change)
What to avoid:
Mechanical cam-based bag length adjustment
Manual film tension adjustment (requires re-threading or roller repositioning)
Fixed-speed motors with mechanical speed variation (no digital control)
For applications where the product dimensions change significantly between SKUs (e.g., small greeting cards vs. large wall calendars), some mechanical components may need to be physically swapped — infeed guides, seal jaws, or forming tubes.
What to look for:
Modular format parts that snap or lock into position without tools
Clearly labeled format parts (product name or SKU code marked on each part)
Dedicated storage rack for format parts at the machine (not in a central toolroom)
Color-coded format parts that match the product recipe on the HMI
What to avoid:
Format parts stored in a central toolroom (adds travel time to every changeover)
Unlabeled format parts (operators waste time identifying the correct part)
Format parts that require tools to install or remove
These are realistic changeover time targets for well-designed machines with trained operators following a documented changeover procedure:
Changeover Type | Poor Practice | Industry Average | Best Practice (JEWSHIN) |
Same format, different bag size (digital param change only) | 20–30 min | 10–15 min | 2–5 min |
Different bag size + guide adjustment | 30–45 min | 15–25 min | 5–10 min |
Film roll change (same film type) | 10–15 min | 5–8 min | 2–3 min |
Film type change (different material) | 20–30 min | 10–15 min | 5–8 min |
Complete SKU change (all of the above) | 45–90 min | 25–40 min | 8–15 min |
Changeover Type | Poor Practice | Industry Average | Best Practice |
Bag length change (servo, digital) | 15–25 min | 8–12 min | 2–4 min |
Product width/height change | 25–40 min | 15–20 min | 8–12 min |
Film roll change | 10–15 min | 5–8 min | 2–3 min |
Complete SKU change | 40–75 min | 20–35 min | 10–18 min |
Changeover Type | Poor Practice | Industry Average | Best Practice (JEWSHIN JX-100/200) |
Card size change (same thickness) | 15–20 min | 8–12 min | 3–5 min |
Card thickness change | 10–15 min | 5–8 min | 2–3 min |
Count per pack change (parameter only) | 5–10 min | 3–5 min | < 1 min |
Changeover Type | Poor Practice | Industry Average | Best Practice |
Label roll change (same label size) | 10–15 min | 5–8 min | 2–3 min |
Label size change | 20–30 min | 12–18 min | 6–10 min |
Container size change | 25–40 min | 15–22 min | 8–12 min |
Regardless of machine type, a disciplined changeover follows the same six steps. Document this as a Standard Operating Procedure (SOP) and post it at every machine.
Time: 5–10 minutes before planned stop
Retrieve parameter record sheet for next SKU
Stage next film roll at machine (correct film type and width)
Stage next product batch at infeed
Identify and retrieve any format parts needed (if applicable)
Pre-select next SKU recipe on HMI (if machine allows while running)
Brief operator on any special requirements for next SKU
Complete current batch — run out remaining product and film where practical
Time: 2–5 minutes
Run machine to a clean stop (not an emergency stop)
Clear all product from infeed, machine, and discharge
Remove remaining film from machine (if film type is changing)
Clean sealing jaws while still warm (30 seconds — much faster than cold cleaning)
Log completion of previous batch (quantity, any quality issues)
Time: 3–10 minutes (tool-free machines)
Adjust infeed guide width to new product dimensions
Adjust discharge guide width
Adjust product height guides (if applicable)
Install new format parts (if required)
Verify all adjustments against parameter record sheet graduated scale positions
Time: 3–5 minutes
Load new film roll
Thread film through machine path (refer to film threading diagram posted at machine)
Recall next SKU recipe from HMI (one-touch selection)
Verify: bag length, seal temperature, speed, tension settings match parameter record sheet
Time: 3–5 minutes
Run 10–20 trial packs at reduced speed
Inspect: bag dimensions, seal quality, product position, cut location
Adjust any parameters that are out of specification
Run 20–50 packs at full production speed
Final quality check: confirm all parameters are within specification
Record actual parameter settings on parameter record sheet (update if any adjustments were made)
Time: 1–2 minutes
Confirm machine is running at full speed and quality
Log changeover completion time
Update production schedule
Return any unused format parts to designated storage location
You can't improve what you don't measure. Implement a simple changeover time tracking system:
Field | Example |
Date | 2026-05-27 |
Machine | JX-L300 Bagging Machine |
From SKU | Greeting Card A (90×130mm, 1 card/pack) |
To SKU | Red Envelope B (80×170mm, 5 cards/pack) |
Changeover start time | 14:32 |
First good pack time | 14:47 |
Total changeover time | 15 minutes |
Operator | Sarah Chen |
Issues encountered | Film threading took extra 3 min — film path diagram needs update |
Action item | Update film threading diagram for this film width |
Review your changeover log monthly and look for:
Longest changeovers: What's causing them? Machine design? Missing tools? Untrained operators?
High-frequency changeovers: Which SKU pairs change most often? Can scheduling reduce changeover frequency?
Operator variation: Is one operator consistently faster? What are they doing differently?
Recurring issues: The same problem appearing repeatedly signals a systemic fix is needed
Measure current changeover time
↓
Identify the top 3time-consuming steps
↓
Apply SMED principles (externalize, simplify, standardize)
↓
Implement machine or process improvement
↓
Measure new changeover time
↓
Repeat
Most manufacturers who apply this cycle systematically achieve 50–70% changeover time reduction within 6 months — without buying new machines.
The fastest changeover is the one you don't have to do. Smart production scheduling can significantly reduce the number of changeovers per day — without reducing output variety.
Schedule SKUs with similar dimensions and parameters in sequence. The changeover between two similar SKUs takes 5 minutes; the changeover between two very different SKUs takes 20 minutes.
Example — Poor scheduling:
Small card (80×120mm) → Large calendar (300×420mm) → Small card (80×120mm) → Medium notebook (150×210mm)
4 changeovers, all major = 4 × 20 min = 80 min changeover time
Example — Optimized scheduling:
Small card (80×120mm) → Medium notebook (150×210mm) → Large calendar (300×420mm)
2 changeovers: 1 medium (10min) + 1 major (20min) = 30min changeover time
Same four SKUs, same total output — but 50 minutes less changeover time per day.
Instead of running small batches of each SKU daily, run larger "campaigns" — produce a full week's or month's supply of each SKU in one run, then changeover. This reduces changeover frequency dramatically.
Trade-off: Higher finished goods inventory. Evaluate whether the inventory carrying cost is less than the changeover cost. For most manufacturers, it is — especially for slow-moving SKUs.
If one or two SKUs represent 60%+ of your volume, consider dedicating a machine to those SKUs and using a second machine for all other SKUs. This eliminates changeovers on the high-volume machine entirely.
Optimizing changeover on a single machine is straightforward. Optimizing changeover on a complete multi-machine line is more complex — because the line is only as fast as its slowest changeover.
Map the changeover time for every machine in your line:
Machine | Changeover Time (Current) | Changeover Time (Target) |
Friction feeder (JX-200) | 8 min | 3 min |
Bagging machine (JX-L300) | 22 min | 8 min |
Sealer / heat tunnel | 12 min | 5 min |
Labeling machine | 15 min | 6 min |
Total line changeover | 22 min (bottleneck = bagging machine) | 8 min |
The total line changeover time equals the longest individual machine changeover — not the sum. Focus your improvement effort on the bottleneck machine first.
On a complete line, multiple operators can work on different machines simultaneously during changeover. This requires:
A written changeover plan that assigns each operator to specific machines
Sufficient operators (or temporary redeployment from other areas during changeover)
Clear communication so all machines are ready before the line restarts
Example: A 4-machine line with one operator per machine can complete a changeover in the time it takes to change the slowest machine — rather than sequentially changing all four machines.
For every SKU, create a one-page line changeover standard work sheet that specifies:
Which operator is responsible for each machine
The exact sequence of steps for each machine
The parameter settings for each machine (from the recipe storage)
The quality verification checks before line restart
Post this sheet at the line start point. When a changeover is called, every operator picks up their sheet and starts immediately — no discussion, no confusion.
Changeover optimization delivers returns through three channels:
Every minute of changeover time reduction translates directly into additional production capacity.
Example calculation:
Current changeover time: 35 minutes
Target changeover time: 10 minutes
Time saved per changeover: 25 minutes
Changeovers per day: 6
Additional production time per day: 150 minutes (2.5 hours)
Line output value: $2,500/hour
Additional daily production value: $6,250
Annual additional production value (250 days): $1,562,500
If changeover time is currently causing production shortfalls that require overtime to recover, reducing changeover time directly reduces overtime costs.
Faster changeovers allow smaller batch sizes, which means:
Lower finished goods inventory
Faster response to customer orders
Ability to take smaller orders profitably
Reduced risk of obsolete inventory for seasonal or promotional SKUs
A: With a well-designed machine (tool-free adjustment, parameter storage) and a trained operator following a documented SOP, most manufacturers achieve near-optimal changeover times within 2–4 weeks of commissioning. The learning curve is primarily about operator familiarity with the machine and the SOP — not technical complexity. JEWSHIN provides a changeover procedure guide and parameter record sheet template with every machine, and our commissioning training specifically covers changeover procedure. Most customers report hitting their target changeover times within the first month of production.
A: JEWSHIN's bagging machine range is specifically designed for wide format ranges. The JX-L300 handles bag widths of 30–160mm and bag lengths up to 330mm — suitable for small cards through medium notebooks. For larger formats including A3 calendars (up to 350mm wide, 480mm long), the JX35-50 is the appropriate model. Both machines feature tool-free size changeover and digital parameter storage. If your range spans both small and large formats, we can design a line configuration that handles the full range — contact our engineering team with your complete SKU list and we'll recommend the optimal configuration.
A: With a 10-minute changeover time and a machine running at 100 bags/min, a batch of 500 units represents just 5 minutes of production — meaning changeover time exceeds production time. In this case, the economics favor either larger batch sizes (campaign production) or a dedicated machine for that SKU. As a general rule, batch sizes should be at least 3–5× the changeover time in production minutes. With a 10-minute changeover, aim for minimum batch sizes of 30–50 minutes of production. Our engineering team can help you analyze your SKU mix and batch sizes to recommend the optimal line configuration and scheduling strategy.
A: For parameter changes (bag length, speed, temperature), JEWSHIN's servo-driven machines effectively achieve automatic changeover — the operator selects the next recipe on the touchscreen and the machine adjusts all parameters instantly. For mechanical adjustments (guide width, height), fully automatic changeover requires motorized adjustment axes — available on higher-specification models for customers with very high changeover frequency (10+ changeovers per shift). Contact our engineering team to discuss automatic mechanical adjustment options for your specific application.
A: JEWSHIN provides a complete operator training package that makes changeover training self-sufficient: a step-by-step changeover procedure guide, a parameter record sheet for each SKU, and video training covering the full changeover process. For new operators, we recommend: (1) review the written changeover SOP; (2) observe an experienced operator perform two complete changeovers; (3) perform two supervised changeovers independently; (4) perform changeovers independently with time tracking. Most operators are proficient within 3–5 days. For facilities with high staff turnover, we recommend laminating the changeover SOP and posting it at the machine — so any operator can follow the procedure correctly on their first day.
A: For JEWSHIN machines, we can supply upgraded format parts, parameter record sheet templates, and changeover procedure documentation at any time. For third-party machines, we can assess the changeover improvement potential and recommend solutions — including replacement with a JEWSHIN machine if the existing machine's design fundamentally limits changeover speed. Contact wendy@jewshin.com with your machine model and current changeover time, and we'll advise on the most cost-effective improvement path.
A: Yes. For OEM customers and distributors who serve markets with high SKU variety (printing, promotional products, cosmetics gift sets), JEWSHIN offers custom-configured machines optimized for changeover speed — including extended recipe storage (100+ recipes), motorized guide adjustment, and custom format part sets for specific SKU ranges. These configurations are developed in collaboration with the OEM customer's engineering team. Contact Wendy Liu directly at wendy@jewshin.com to discuss OEM configuration options.
Cutting changeover time by 50–80% is achievable for most manufacturers — but it requires action on three fronts simultaneously:
Front | Key Actions | Expected Impact |
Machine design | Tool-free adjustment, servo control, parameter storage | 40–60% time reduction |
Process discipline | SMED methodology, SOP documentation, parallel changeover | 20–30% additional reduction |
Scheduling optimization | SKU grouping, campaign production, dedicated lines | 20–40% reduction in changeover frequency |
Applied together, these three fronts can reduce your total annual changeover time by 70–80% — recovering hundreds of hours of production capacity per year.
JEWSHIN's engineering team can assess your current changeover process and recommend specific machine and process improvements — including a projected changeover time reduction and ROI calculation.
To request a free changeover assessment, share:
Your current machine types and models
Number of SKUs run per shift
Current average changeover time
Your biggest changeover pain point
We'll respond within 24 hours with specific recommendations.
Email: wendy@jewshin.com WhatsApp: +86-13128136672
Submit your inquiry: www.jewshin.com
Related Reading:
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Packaging Automation ROI Calculator: Build Your Business Case →
How a Game Card Factory Packages 10 Card Types at 240 Bags/Min →
Shrink Wrap vs. Flow Wrap vs. Bagging: Which Packaging Method Is Right for You? →
About the Author: Wendy Liu is the CEO of Dongguan Jewshin Intelligent Machinery Co., Ltd., a manufacturer and global exporter of automated packaging machines and turnkey line solutions. JEWSHIN's founding team brings 15+ years of packaging machinery engineering experience, with 200+ machine models exported to 80+ countries across North America, Western Europe, Southeast Asia, the Middle East, South America, and Africa. Explore our full product range →
