Changeovers were eating a full shift every week. Here is how the plant got it back without new presses.

Start on the floor

Every engagement begins with observation. We time real cycles across every shift, talk to the people running the line and map where minutes disappear. The data almost always tells a different story from the monthly report.

That first picture sets the baseline every later change is measured against.

Change what matters first

Once losses are sized, the order of work becomes obvious. We tackle the largest, most certain gains first and leave expensive equipment decisions until the process is stable.

Make it stick

Gains hold when the plant team owns the routine that protects them. We build short daily reviews, clear standards and simple visual signals so the improvement survives long after we leave.