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Eliminating production losses in changeover operations: a case study on a major European food manufacturer

Lookup NU author(s): Dr Ying Yang



This work is licensed under a Creative Commons Attribution 4.0 International License (CC BY 4.0).


With the application of Advanced Manufacturing Technologies (AMTs), food manufacturers can operate outside of traditional volume-variety diagonal positions without the predicted performance penalties. Although food manufacturers produce high-variety and high-volume products with low cost and high quality, it is unavoidable that their high-variety production processes experience a high changeover frequency. Changeovers are not only time consuming, but are also accompanied by production losses. While the literature has emphasised the technical and technological aspects of changeovers, e.g. the Single Minute Exchange of Dies (SMED), most of these studies focused on flexibility, time and product quality. As food manufacturers’ production is capital-intensive with low profit margins, it is essential for them to improve changeover efficiency and reduce changeover losses. This paper thus aims to understand changeover activities, identify the key factors influencing food losses during changeovers and develop a mechanism for improving overall production efficiency. To that end, an in-depth case study was conducted with a major European food manufacturer. This study identified nine key factors influencing changeover losses and developed an improvement framework with three key themes (working methods, knowledge management and organisational design).

Publication metadata

Author(s): Stapelbroek M, Kilic O, Yang Y, Van Donk D P

Publication type: Article

Publication status: Published

Journal: Production Planning and Control

Year: 2022

Issue: ePub ahead of Print

Online publication date: 25/10/2022

Acceptance date: 11/10/2022

Date deposited: 03/10/2022

ISSN (print): 0953-7287

ISSN (electronic): 1366-5871

Publisher: Taylor & Francis


DOI: 10.1080/09537287.2022.2136041


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