Define the complete route from the last accepted pack of one run to the verified first accepted pack of the next, including safe isolation, parts, recipes, cleaning and quality release.
1. Define the changeover boundary and release condition
Measure and manage the whole change, not only the time spent adjusting one machine. The starting condition might be the last accepted pack of the previous run; the end condition should be the first verified accepted pack of the next run with the line stable, correct components loaded and required checks complete.
Separate product change, pack-format change, label or code change, cleaning and planned maintenance. They can overlap, but each has different evidence and responsibilities.
2. Build format families and a change-part register
Group formats by the changes they actually require. Two containers with similar nominal volume may need different guides, starwheels, filling nozzles, cap handling, label sensors or case patterns. Record each part, storage location, machine, format compatibility and inspection status.
| Control item | Record | Verification |
|---|---|---|
| Change parts | Unique identity, machine, format and revision | Condition and completeness before setup |
| Mechanical settings | Guide positions, heights, stops and tooling references | Position indicator or approved setup check |
| Recipe | Format identifier and protected parameters | Line-wide match and authorised selection |
| Packaging components | Container, closure, label, code and case version | Line clearance and component check |
| Quality release | First-off sample requirements | Named approval and retained record |
3. Move external work away from stopped production time
Before the line stops, stage clean change parts, tools, approved components, documentation and any lifting aids. Check that parts are complete and undamaged. After the previous run, move removed parts to a defined cleaning or inspection route rather than leaving them around the line.
- Prepare the approved changeover instruction and format record.
- Confirm the next product and component versions.
- Stage tools and parts in sequence of use.
- Arrange waste, residual product and line-clearance containers.
- Identify tasks that require safe isolation or specialist access.
- Schedule first-off quality checks and release authority.
4. Make safe isolation part of the written sequence
Some adjustments can be made from protected controls; others require access to guarded or energised areas. The changeover instruction should distinguish them and follow the site’s safe system of work. Stored pneumatic, hydraulic, electrical, gravitational or thermal energy must be considered before access.
The HSE’s work-equipment maintenance guidance emphasises planned safe isolation and control of stored energy. A competent site-specific assessment must define the actual procedure.
5. Coordinate the sequence across the complete line
A line change can fail when one machine remains on the previous format or when guides are adjusted independently at the same transfer. Use a line-level sequence with named ownership. Start from the physical format path, then apply recipes, coding and inspection settings, and finally run controlled first-off packs.
| Stage | Key control |
|---|---|
| Clear and identify | Remove previous product and components; reconcile or quarantine residual packs |
| Safe and access | Apply the approved stop, isolation and access method |
| Change and inspect | Fit verified parts and set mechanical references |
| Select and verify | Load the correct recipe, code, label and inspection configuration |
| Dry or controlled test | Check transfers and functions before committing production material where appropriate |
| First-off release | Produce, inspect and approve the defined sample before normal release |
6. Define cleaning by product risk and equipment boundary
The buyer’s quality and safety requirements determine whether a wipe-down, strip clean, wash, flush, clean-in-place sequence or validated process is needed. Map product-contact parts, splash zones, conveyors, reject systems, guards and tools. State who supplies cleaning media and how the clean condition is checked.
Cleaning can affect seals, sensors, labels, lubrication and electrical equipment, so the method must match the machine design. Never assume that a generic washdown route is suitable.
7. Learn from each changeover
Record the sequence, delays, missing parts, repeated adjustments, first-off failures and post-start corrections. Separate normal work from avoidable loss. Improvements may involve better staging, clearer references, revised tooling, recipe controls, component quality or a design change.
- Last accepted old-format pack and first accepted new-format pack
- Time lost waiting for parts, materials, approval or isolation
- Mechanical or recipe corrections after first-off
- Scrap, rejects and residual product
- Safety or access observations
- Actions, owner and verified update to the standard work
Use the sample and trial guide for new formats and the troubleshooting guide when faults appear only after a change.