1. Control the tip of the iceberg: production losses due to series changes

In many industries, particularly those linked to innovation, one of the main reasons for production losses is the loss associated with changeovers. Between 10% and 20% of production time can be devoted to series changeovers –, which is the same amount of time during which machines or lines are not producing.

One of the main causes of this loss of production, and above all of its tendency to increase, is the growing diversity of references, notably linked to innovation.

When introducing an innovation, we need to take into account two potentially unfavorable effects on these series changeover times:

• The introduction of new SKUs increases, all other things being equal, the need for series changes and therefore, proportionally, the time required for these changes (or, alternatively, by keeping...