Reducing changeover time in the printing process

Abstract

This study explores strategies to reduce the changeover time in the printing process. The current changeover time is affecting the operational efficiency of the offset unit. The research focuses on a comprehensive analysis of the current changeover process, identifying inefficiencies and recommending strategies to reduce changeover time. Data was gathered through observations, unstructured interviews, and production logs, and analysed with tools such as Root Cause Analysis, Value Analysis, and Single-Minute Exchange of Die (SMED). The paper also presents recommendations through the implementation of ECRS (Eliminate, Combine, Rearrange, and Simplify), SMED, and 5S methodologies and suggestions for improvements that significantly reduce the overall changeover time. Beyond the printing industry, this study offers valuable insights for various industries that seek to optimise changeover processes. The structured methodologies presented here can serve as a framework for reducing changeover time, minimising waste, and improving workflow efficiency across diverse industrial contexts, thereby lowering operational costs and boosting productivity.