Question 1

What is ProChangeover?

Accepted Answer

ProChangeover is software that runs SMED-based changeover workflows on the shop floor. Operators follow a live digital task list, each step gets a timestamped sign-off, and you get a Gantt timeline of every completed run. It replaces paper sheets and verbal handoffs with a single shared execution record.

Question 2

How long does setup take?

Accepted Answer

Most teams are running their first live changeover within a day. You define your products, map the task sequence for each product pair, then start a run. There is no IT project required and no installation — it is a web app.

Question 3

Do operators need to learn new software?

Accepted Answer

No. The operator interface is a checklist — large tap targets, no login friction, and no typing required for standard execution. It works the way paper sheets do, just live and digital. Teams that said "our operators won't use an app" typically have everyone running within a shift.

Question 4

Does it work on tablets?

Accepted Answer

Yes. ProChangeover is a web app — no install needed. It works on tablets and desktops and is optimised for floor use with large touch targets and high-contrast status indicators.

Question 5

How much does ProChangeover cost?

Accepted Answer

$49 per month. That includes unlimited production lines, unlimited changeovers, real-time sync across your whole shift team, timestamped sign-off and searchable run history, and a Gantt-style timeline for every completed run. No per-seat pricing, no hidden limits.

Question 6

What is SMED?

Accepted Answer

SMED stands for Single Minute Exchange of Die. It is a lean manufacturing method for reducing changeover time by separating internal tasks (which require the machine to be stopped) from external tasks (which can be done while the machine is still running), then converting internal tasks to external wherever possible. SMED implementations commonly reduce changeover time by 30–50%.

Question 7

What's the difference between internal and external changeover tasks?

Accepted Answer

Internal tasks require the machine to be stopped before they can start — for example, swapping a mould or adjusting a temperature setpoint that needs the line down. External tasks can happen while the machine is still running — for example, staging tooling, pre-heating components, or preparing materials. SMED's core move is identifying tasks that are unnecessarily internal and shifting them out.

Question 8

How does ProChangeover implement SMED?

Accepted Answer

You configure task sequences per product pair. The system generates the right task list automatically when a run starts, enforces the step order, captures a timestamp at each sign-off, and produces a Gantt timeline showing where time was lost. Over time you can identify which steps are internal vs external, tighten standards based on actual data, and track whether changes are sticking.

Question 9

Can we have different task lists for different product changeovers?

Accepted Answer

Yes. You define separate task sequences per product pair — SKU-A to SKU-B is treated differently from SKU-B to SKU-C. The system selects the right task list automatically when a run starts based on the from-product and to-product you select.

Question 10

How do supervisors know a changeover is running long before it ends?

Accepted Answer

The live task board shows real-time progress for all active changeovers. Delays are flagged as they happen — not discovered in a debrief after the line is already late. A supervisor can see from any device which step is behind and who owns it, without walking the floor.

Question 11

How does sign-off work?

Accepted Answer

Each operator marks their assigned step complete in the app. The timestamp, task name, and operator role are recorded immediately in the run record. Steps cannot be bypassed without leaving a trace — if something is marked complete late or skipped, the timeline shows the gap.

Question 12

Can operators leave notes during a run?

Accepted Answer

Yes. Operators can attach a plain-text comment before marking a step complete — for example, "torque settled on third attempt" or "pressure took longer than expected, filter may need checking". Comments are timestamped, attached to the run record, and visible in post-run review. Engineers can review patterns without needing to interview anyone.

Question 13

What does the post-run Gantt show?

Accepted Answer

A task-level timeline of the full changeover — who did what, in what order, how long each step took compared to the standard, and where overlap was missing. The Gantt is searchable across runs and filterable by line and shift.

Question 14

Can we access historical records for audits?

Accepted Answer

Yes. Every run produces a timestamped, searchable sign-off record that is permanent and tamper-evident. If an auditor asks for records from six weeks ago, you can pull them in seconds — no reconstructing from memory.

Question 15

Can ProChangeover manage changeovers across multiple lines at the same time?

Accepted Answer

Yes. There is no limit on production lines. Supervisors see all active changeovers in a single dashboard — each line with its own live task board, real-time progress, and delay flags. You can run changeovers simultaneously on five lines and monitor all of them from one screen without switching views.

Question 16

Our operators will not use an app. Is this realistic?

Accepted Answer

The interface is intentionally simple — it is a checklist, not ERP software. There is no typing for standard execution, no navigation, no login friction on the floor device. The most common objection before rollout is adoption; the most common surprise after rollout is that operators prefer it to paper because they can see what everyone else is doing in real time.

Question 17

Do we need to roll it out across all lines at once?

Accepted Answer

No. The recommended approach is one line, one product pair, one shift. Once you have a run logged and a timeline to look at, you will know whether it fits your operation before expanding. Most teams are confident by run three.

Question 18

What if our changeovers are too different to standardise?

Accepted Answer

That is exactly what the product-pair configuration handles. Each combination of from-product and to-product gets its own task list, step sequence, and target specs. You are not forced to use a single template across every run — the system is built around the reality that switching from SKU-A to SKU-B and from SKU-B to SKU-C are different jobs.

Question 19

What does getting started look like — is there onboarding support?

Accepted Answer

Setup is fully self-serve. Most teams are live within a day: define your products, map the task sequence for your first product pair, and run a changeover. If you want guidance, an optional onboarding call is available — you can request one via the contact page after signing up. There is no IT project and no implementation fee.

Question 20

How do we measure whether changeover time actually improved?

Accepted Answer

The Gantt timeline gives you a baseline after run one. Every subsequent run is compared against it automatically. You can see which steps, roles, and shifts are driving variance — and whether changes to the standard are working. The data is at the task level, not just total changeover duration.

Question 21

How much time do manufacturers typically save?

Accepted Answer

SMED implementations commonly reduce changeover time by 30–50%. ProChangeover gives you the data to know where your time is going and track whether changes stick. The results depend on your starting point — teams with no prior standard typically see larger early gains, since the first improvement is just executing consistently.

Question 22

What is OEE and how does changeover time affect it?

Accepted Answer

OEE stands for Overall Equipment Effectiveness — the standard metric for manufacturing productivity, calculated as Availability × Performance × Quality. Changeover time directly eats into Availability: every minute a line is stopped for a changeover is a minute it cannot produce. For most manufacturers, changeover is the single largest planned source of downtime and therefore the easiest lever to move OEE. Reducing a 40-minute changeover to 25 minutes on a line that changes over twice per shift recovers 30 minutes of production capacity every shift, every day.

Question 23

How do we calculate what a slow changeover is costing us?

Accepted Answer

Multiply the overrun in minutes by your line's output value per minute. For example: if your line produces $500 of output per hour and a changeover runs 20 minutes over standard, that overrun costs $167 in lost capacity per run. If that line does two changeovers per shift, five days a week, the annualised cost of that single 20-minute gap is over $86,000 in unrecovered production time — before accounting for overtime or schedule knock-on effects. ProChangeover gives you the task-level data to identify exactly which step is causing the overrun.

Question 24

Does ProChangeover integrate with our ERP or MES?

Accepted Answer

Not currently. ProChangeover runs as a standalone web app. ERP and MES integration is on the roadmap — contact us if this is a requirement for your evaluation.

Common questions about ProChangeover

Getting started

SMED and the methodology

Features

Adoption and rollout

ROI and measurement

Integration and security

Your first standardized changeover is one week away.