Kestrel Line Systems
Format changeovers on line 2 cut from 52 to 31 minutes
How a snack producer made every carton-size change follow the same steps, with our quick-change guides and one setup sheet.
01
At a glance
Case at a glance
| Customer | Snack producer with three packaging lines |
|---|---|
| Line | Cartoning line 2 · the same four carton sizes before and after |
| Applied | QC-200 quick-change guide set · one shared setup sheet |
| Measured | 8 weeks before and 8 weeks after · 40 changeovers in each period |
02
Challenge
Every shift set up the line its own way
Line 2 changes carton size three to four times a day. Each shift found the guide positions with trial runs, so the same change took 35 minutes on one shift and over an hour on another.
Cartons jammed in the first minutes after a change, and the line ran slow until someone adjusted the guides by hand.
03
Solution
Fixed reference points and one setup sheet
We fitted the QC-200 guide set, which locks each guide at a marked position for each carton size. Nobody has to find the position with trial runs.
One setup sheet lists the same steps in the same order for every shift. The line supervisor signs it off after the first good carton.
04
Use cases
What changed
Shorter changeovers
Average changeover time fell from 52 to 31 minutes, measured on the same line with the same carton sizes.
Same steps on every shift
The line supervisor recorded that all three shifts followed the setup sheet in the same order.
No hand adjustment after a change
The guides no longer had to be reset during the first run after a change.
Key figures
Measured on line 2
52
average changeover before (40 changeovers, 8 weeks)
31
average changeover after (40 changeovers, 8 weeks)
40%
shorter average changeover on the same line
05
Products
Used on this line
QC-200 quick-change guide set
Indexed side guides and stops that lock at a marked position for each carton size.
- Up to 8 carton sizes
- Tool-free locking
- Lanes 300–600 mm
Setup sheet service
We write the setup sheet with your line team and train each shift on it.
- One sheet per line
- 2 days of on-site training
06
FAQ
Questions about this case
Can a case be published without the customer's name?
Yes. Describe the customer by industry and size, as here, and keep each measured result with its conditions.
Will our line get the same result?
It depends on the line, the formats, and how often you change them. We measure your current changeovers first and tell you what to expect.
Contact
Applications desk
- cases@example.com
- Phone
- +1 555 0142
- Hours
- Mon–Fri 8:00–17:00