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SMED Consulting

Is Your Changeover Time Killing Your Profits?

Every minute your machine sits idle during changeover is money walking out the door. 

You know the frustration. Your production line stops for what should be a “quick” changeover. Two hours later, you’re still waiting. Meanwhile, orders pile up, customers get impatient, and your competitors are shipping products while you’re still fumbling with setup. 

If this sounds familiar, you’re not alone. But you don’t have to stay stuck. 

Live Training Examples

The Hidden Profit Killer in Your Plant

Most plant managers focus on the big problems—equipment breakdowns, quality issues, material shortages. But there’s a silent profit killer that’s probably costing you more than all of these combined: inefficient changeovers. 

Think about your last changeover: 

How long did it really take?
How many people were involved?
How much production did you lose?
What did it cost in overtime, expediting, and frustrated customers?

Now multiply that by every changeover you do. 

The numbers are staggering, aren’t they?

The Real Cost of Slow Changeovers (It's Worse Than You Think)

What You Can See:

  • Lost Production: Hours of downtime per changeover 
  • Labor Waste: Multiple operators standing around during setup 
  • Rush Charges: Expediting materials and shipping to catch up 
  • Inventory Costs: Making large batches to avoid frequent changeovers 

What You Can't See (But Your Wallet Feels):

  • Lost Sales: Customers who can’t wait and go elsewhere 
  • Missed Opportunities: Orders you can’t take because you’re not flexible enough 
  • Quality Problems: Rushed setups leading to defects and rework 
  • Employee Frustration: Good people leaving because of chaotic operations 
  • Competitive Disadvantage: Losing market share to more agile competitors 

Here’s the brutal truth: Most manufacturers lose between $500,000 and $2 million annually to inefficient changeovers. 

Why This Hits Plastic, Chemical & Pharmaceutical Companies Hardest

Your industry faces unique changeover challenges that other manufacturers don’t understand: 

Plastic Engineering
  • Complex mold changes requiring precise temperature and pressure adjustments 
  • Material purging between colors or grades 
  • Tooling changes that seem to take forever 
  • Quality validation that adds hours to every changeover 
  • “We can’t afford to run small batches because our changeovers take 4-6 hours. But customers want smaller quantities and faster delivery.” 
Chemical Processing
  • Line cleaning and validation between product runs  
  • Temperature and pressure stabilization 
  • Safety protocols that can’t be rushed 
  • Quality testing before production restart 
  • “Our cleaning procedures between chemical grades take half a day. By the time we’re ready to run, the market has moved on.” 
Pharmaceutical Manufacturing
  • Rigorous cleaning validation between products 
  • Equipment qualification and documentation 
  • Batch record setup and approval 
  • Quality assurance checkpoints at every step 
  • “FDA compliance means our changeovers are bulletproof but painfully slow. We’re losing business to companies who figured out how to be fast AND compliant.” 
Packaging Operations
  • Format changes for different package sizes 
  • Label and coding system adjustments 
  • Sealing and cutting parameter changes 
  • Quality checks for new specifications 
  • “Every SKU change shuts us down for hours. We want to offer more variety, but we can’t afford the downtime.” 

The Industries We Transform

Plastic Engineering & Injection Molding, Roto Molding, Blow Molding

  • Mold changeovers from hours to minutes 
  • Color and material transitions without extensive purging 
  • Multi-cavity tooling optimization 
  • Temperature and cycle time standardization 

Chemical & Process Manufacturing

  • Line cleaning and preparation efficiency 
  • Product transition procedures 
  • Safety-compliant rapid changeovers 
  • Batch-to-batch optimization 

Pharmaceutical & Medical Device

  • Validated cleaning procedures 
  • Documentation and batch record efficiency 
  • Compliance-friendly rapid setup 
  • Quality system integration 

Packaging & Converting

  • Format changeovers across multiple package sizes 
  • Label and coding system optimization 
  • Sealing and cutting adjustments 
  • Multi-product line flexibility 
Get a the Ultimate Guide for Rapid Changeover and SME Growth

The Changeover Breakthrough Reshaping Your Industry

Smart manufacturers in your industry have discovered SMED (Single Minute Exchange of Die)—the systematic approach to reducing changeover times from hours to minutes. 

They're using it to:
  • Accept smaller orders profitably 
  • Respond to customer requests instantly  
  • Reduce inventory by 40-70% 
  • Improve delivery performance dramatically 
  • Win business from slower competitors 
While you're stuck with long changeovers, they're:
  • Shipping products faster 
  • Offering more flexibility 
  • Capturing market share 
  • Growing their margins
The SMED Breakthrough: From Hours to Minutes

SMED isn’t magic—it’s methodology. Developed at Toyota and perfected in manufacturing plants worldwide, it systematically eliminates changeover waste through four proven steps: 

  • Separate what can be done while running vs. stopped 
  • Move as much as possible to “while running”  
  • Streamline everything that must be done while stopped 
  • Perfect the preparation process 

The result? Changeovers that used to take 4-6 hours now take 15-30 minutes. Quality improves. Stress decreases. Profits soar. 

The SMED Breakthrough: From Hours to Minutes

SMED isn’t magic—it’s methodology. Developed at Toyota and perfected in manufacturing plants worldwide, it systematically eliminates changeover waste through four proven steps: 

Separate what can be done while running vs. stopped

Streamline everything that must be done while stopped

Move as much as possible to "while running"

Perfect the preparation process

The result? Changeovers that used to take 4-6 hours now take 15-30 minutes. Quality improves. Stress decreases. Profits soar. 

The Real Cost of Slow Changeovers (It's Worse Than You Think)

Success Stories from Companies Just Like Yours

Plastic Injection Molding Company

Before: 4-hour mold changes, limited to long production runs, losing small-batch business  

After: 22-minute changeovers, 300% increase in product variety, $1.2M additional annual revenue “We went from dreading changeovers to embracing them. Now we can say ‘yes’ to orders we used to turn away.” 

Chemical Processing Plant

Before: 6-hour line cleaning between products, massive inventory requirements 

After: 45-minute transitions, 60% inventory reduction, improved cash flow by $800K “Our customers noticed immediately. Lead times went from weeks to days.” 

Pharmaceutical Packaging

Before: 3-hour format changes, FDA compliance concerns, limited flexibility 

After: 18-minute changeovers, full regulatory compliance, 400% improvement in OTIF delivery “We proved you can be fast AND compliant. Our competitors are scrambling to catch up.” 

The Problems SMED Solves in Your Operation

SMED isn’t magic—it’s methodology. Developed at Toyota and perfected in manufacturing plants worldwide, it systematically eliminates changeover waste through four proven steps: 

Low Productivity
  • Eliminate hours of downtime per changeover
  • Increase effective production time by 20-40%
  • Get more output from existing equipment 
High Production Costs
  • Reduce labor waste during changeovers
  • Lower inventory carrying costs
  • Eliminate overtime and expediting fees 
Poor OTIF (On-Time In-Full) Delivery
  • Meet customer deadlines consistently
  • Respond to rush orders without chaos
  • Build reputation for reliable delivery 
Limited Flexibility
  • Accept smaller batch orders profitably
  • Offer more product variety
  • Respond quickly to market changes 
Quality Issues
  • Eliminate setup-related defects
  • Standardize changeover procedures
  • Reduce first-piece rejection rates 
Employee Frustration
  • Remove chaos from the changeover process
  • Give operators procedures that actually work
  • Build pride in smooth operations 

The result? Changeovers that used to take 4-6 hours now take 15-30 minutes. Quality improves. Stress decreases. Profits soar. 

Why quick Changeovers Matter More Than Ever

Customer Expectations Have Changed
  • Shorter lead times demanded 
  • Smaller batch sizes requested  
  • More product variety expected 
  • Perfect delivery performance required 
Market Reality Check
  • Global competition intensifying 
  • Margins under constant pressure 
  • Supply chains more volatile 
  • Flexibility = survival 

The Bottom Line Companies with quick changeovers win. Companies with slow changeovers lose market share, customers, and profitability. Which category is your company in? 

The Cost of Waiting Another Day

Every day you delay addressing changeover inefficiency: 

You lose money
  • Production capacity sits idle 
  • Labor costs accumulate without output 
  • Expediting fees mount up 
Customers get frustrated
  • Delivery promises get harder to keep 
  • Small orders remain unprofitable 
  • Competitors look more attractive 
Opportunities slip away
  • New products can’t be tested quickly 
  • Market changes catch you unprepared 
  • Revenue growth stalls 
Your team gets demoralized
  • Chaos becomes “normal” 
  • Good people start looking elsewhere 
  • Improvement seems impossible 

The result? Changeovers that used to take 4-6 hours now take 15-30 minutes. Quality improves. Stress decreases. Profits soar. 

What Makes GreenDot Different

Real Experience, Real Solutions

We didn’t become changeover experts by studying case studies. We earned it by managing production lines where every changeover minute mattered. We’ve been responsible for P&L statements where changeover inefficiency killed profitability. We’ve managed teams where changeover days were everyone’s least favorite days. 

The difference? We figured out how to turn changeover chaos into competitive advantage. Now we help others do the same. 

We Focus on Your Industries 25+ years working specifically with plastic, chemical, pharmaceutical, and packaging companies. We understand your unique challenges, regulatory requirements, and competitive pressures. 

We Deliver Results, Not Reports Our success is measured by your changeover times, not our PowerPoint presentations. We work on your production floor until the improvements stick. 

We’ve Been There 500+ changeover transformations across companies just like yours. We know what works, what doesn’t, and how to make change happen even in the most challenging environments. 

is Your Operation Suffering From:

Time Problems?
  • Changeovers taking hours when they should take minutes 
  • Production schedules controlled by changeover limitations
Money Problems?
  • Small orders that aren’t profitable 
  • Growing inventory costs from large batch production 
Customer Problems?
  • Missed delivery promises 
  • Lost business to faster competitors 
Quality Problems?
  • Defects and waste after every changeover 
  • Inconsistent results depending on the operator 

If any of these hit home, SMED is your solution. 

Check out our testimonials

"Better Consulting option for MSMEs "

Meera Industries Limited Independent Director

"Nirav has communication skills to get connected with hard working dedicated employees. He supports to bring each employee to visualize broad spectrum role. "

Atul Limited Senior Executive

"Mr. Nirav Trivedi is an excellent coach both on personal and professional front. He has exceptionally curated his TQM course to identify gaps and increase productivity in sort span of time. I wish him and his team best of luck for all endeavors. "

Atul Limited Assistant Manager

"A person with who can create a roadmap to build strong value and take you to the next level "

MAAK & Associates Managing Partner

"Had a very good experience working with Greendot Consultancy, we have been resulted into skill improvement and develop personal view to grow our company and how to balance industry in many aspects. "

Alltech Industries Director Of Design, Operation and After Sales

"Mr. Nirav Trivedi is a excellent business consultant we have work with so far. His advice as a consultant has allowed our organisation to expand our business tremendously. He has helped us to implement changes in our policies and strategies that have made our organization more efficient and profitable. He is costliest among all the consultants, but WORTH IT ! "

Alltech Industries Director

"Practical and Innovative way to resolve problems. Highly positive attitude. Implementation of suggested modification and changes is easier. "

Chiripal Polyfilms Senior Manager QC,TS

"Have been associated with Nirav's team, Green Dot for 2 years. These two years were quite focused on our objective and the goal set by the organization. Despite Covid lockdown we could achieve a successful milestone. Support extended by Nirav and team was just fantastic. Thanks Nirav, "

Atul Limited Vice President

"Nirav is an excellent Management Consultant. His company was appointed by our customer for Vendor Management Program, which included 5S and Lean Management practices. The program was quite effective. Later we engaged him for Strategic Management Program. This program is excellent and very effective. I recommend this program to companies who wants to take benefit from this.. "

Prima Automation (India) Pvt.Ltd Managing Director

"I am working with greendot since last 12 + year. We are consistently improving our business process and Improved our productivity in paper mill and corrugation industries. In last couple of month we have increased our productivity by around 20% by implementing lean practice. Amazing productive experience with team greendot. They are the only consultant who can retain a client for this much duration and helping our industries to grow. "

RBR Papers LLP Founder

"Nirav Trivedi is an excellent management consultant & coach. He and his team at Greendot has been helping multiple industries in improving productivity and reducing cost by training manpower to optimize processes and increase capacity of machines. I highly recommend his knowledge and expertise in this area. "

Accenture Application Development Associate Manager

"Nirav Trivedi as I know him, has very good communication skill along with imparting training in an easy and understandable language. His expertise lies on Lean management, TQM,TPM, 5S, EMS/EHS and other operational management tools and systems through which he transforms the organization to world class facility. He is consultant to organization. Though, when associated, he becomes part of organization and be a team member to take the organization to next levels. This is one of the best practices which I feel is the success of Mr. Nirav Trivedi. I wish him all the best for all is future endeavors and would be pleasure to be in continuous connect and get benefitted with his knowledge and experience. Regards "

Sangir Plastic Vice President Head Operation & NPD

"We have worked with Mr Nirav Trivedi and Green Dot team for 5S implementation and journey is so good so far. 5S is not only house keeping improvement but it will help us in many other areas viz. productivity, inventory, money generation by identifying unwanted items, motivation and many more. "

Atul Limited Head of Engineering

"Best in class Consultant for Business System development "

Shah Traders (Vapi) Directors

"I personally Know Mr Nirav Since a Decade Now. Based on My professional experience & feedback from our a few common client of Cps Technologies & Green Dot, i can say Mr Nirav is having rich experience for management consulting in various Industry Verticles incl a working with out of India's clients, Practical approach in Problem Solving & creating A niche segment for his consulting by coaching , consulting & make client practice six sigma , lean management & etc. Techniques successfully. "

CPS Technologies Head – SMB & Corporate Sales

"Green Dot and NIrav Trivedi is very understanding on problems that organisation is facing and suggest remedies which suits to culture and receptiveness of employees to start off. On process improvement and setting best practices He delivers worth for company, particularly. We worked with him and satisfied with services he delivered. All the best and keep nurturing on. "

Rajhans Group of Industries General Manager Operations

"I am enjoying with his consultation.if u want your business in automode i strongly recommend Mr Nirav Trivedi.i am in Automode r u? jaha apni soch bandh ho jati hai waha se unki soch suru hoti hai. Thank you Nirav Sir. "

Jalaram Khichdi Owner

"Most Reliable consultant, Bring our company to the next level now able to drive the company towards desire mission "

Jalaram Khichdi Director

"Industry specific bull's eye approach with their expertise is an effective combination in Greendot's management, for industries to upgrade their operational standards... "

Sahajanand Valves Vise President of Engineering

"Nirav, has worked with our Cluster for Lean Mfg implementation. He is constantly striving for excellence in his chosen domain and working hard towards his goal to taking Green Dot to the next level. Immense clarity of thought, good methodology for implementation across wide spectrum of Industries, keeping himself abreast with latest theories. He is a good orator and a good influencer. I highly recommend Nirav to those who are seeking business solutions for the better. "

RBD Engineers Pvt Ltd Managing Director

"GreenDot Consulting lead by dynamic Nirav Trivedi is highly recommendable. He is one of those consultant who has entrepreneurs mindset. Someone who knows to walk on the edge & help his clients get best out of the services provided. I believe he has good grip & insight for MSMEs. Best wishes "

Acme Creation (Logo Missing) Managing Director

"I know Nirav for many years, he is very committed to his work and his problem solving ability is his biggest asset. He always sets very high standards for him and his team which is difficult for others to match. Wish him all the best in future! "

Firmenich Associate Director

"I know Nirav ji from last 5 years and I had learned a lot from him specially how to make consistent growth in career, excellent personality with in depth knowledge Truly it was Great experience to be connected with you....Thanks for being my connection "

Pacific Group of Companies Owner

Very happy with Greendot's services and their support in continuous development of our organization. Over an year we have not only managed to keep our inventory under control, but also improved productivity. Our profit has increased , cost has minimized and we are currently able to utilize our capacity in very efficient manner. In addition to this, we have also managed to integrate all departments through one system. Greendot team members are very professional, always supportive, polite and have helped our employees adapt to change over a short period of time. Under the guidance of Mr. Trivedi's leadership and vision Greendot success is guaranteed.

Kingsley Ecotech Pvt Ltd Director

Very Professional on Management !

Hebei Yitaike Bearing Co.,Ltd - ETK Bearings Senior Business Development Manager

Very Professional on Management !

Hebei Yitaike Bearing Co.,Ltd - ETK Bearings Senior Business Development Manager

"He has immense and thorough knowledge of lean management, quality management system and backed by excellent academic. projects taken care by Nirajji is always hv a new experience and on time completion. "

JSW MI HR Head

"Good experience of having interacted with Mr. Nirav Trivedi. He delivered a motivational speech for undergraduate Chemical Engineering students at SCET during my tenure as Head of Chemical Engineering "

Sarvajanik College of Engineering & Technology Professor

"Nirav is a good human being to work with and a highly professional management consultant. He has been instrumental in helping many organisations for course correction. wishing him all good things ahead. "

SEC GLOBAL CONSULTING AND INITIATIVES LLP CEO

"Nirav has innovative thoughts and I like his management tips. "

Shreemad Rajchandra Trustee

"I would like to recommend Mr.Nirav Trivedi as a management consultant and productivity coach, Himal. "

HMC Sales Owner

"Nirav is one of the most dynamic, versatile person i have ever came across in my professional career. He is one of the best management consultant we have in the whole Gujarat State. He has done some amazing assignments which resulted in huge cost savings , increased productivity for his clients and in some cases he along with his team managed to turn around the companies with their in depth knowledge of the subject matter. He & his team spends great amount of time to understand the root cause of the client & then they come up with the customised solution for them. I wish nirav & his team all the very best & i am sure nirav along with his team of green dot will create many more wonders in the corporate world with their expert knowledge. All the best nirav!! Keep doing the good stuff & keep helping the corporates to evolve & grow!! "

White Turtle Consulting and K&K Associate Co-Founder

"I was looking for an HR consulting firm and came across Nirav and his organization. Having worked with various consultants, I expected the same stuff but was pleasantly surprised to find his methods refreshingly different. Here was also a consultant who guaranteed a positive change... what could be more interesting? We are currently working with his firm and moving forward creating agents of change... Would definitely recommend him to anyone "

Vertellus Speciality Materials (India) Pvt.Ltd Director

"Nirav Trivedi is amazing person with great knowledge on team management and also with all the great ideas for growing own business with different tools to have faster and success. All completely solution for business for small and big business.. Amazing person with very down to earth and also ready to help everyone.. "

Imperial Overseas Education Consultants( Imperial Platforms Inc) Administrative Assistant

"I Know Nirav more the 20 years , he is Master of Management !! Keep it up "

Indobuilt Storage System Pvt.Ltd Senior Vice President

"Superb insight in Small Business operations. Good at decoding SME bottlenecks. Polite service of the entire Organisation. Very well Read. Recommended for Management Consulting "

Usha Die Casting INDS Senior Vice President

"Nirav & his Tem@ GreenDot Effectively Practices Trade as a Consultant to Various Small to Enterprise Organizations with ease , be it Improving Profitability, Brand Image, HR , Productivity, Efficiency & as team an asset to get associated with ! "

Matrix Network and Solutions Co-Owner

"Good 5s consultant "

Agarkar HR Services Pvt Ltd Director

"I highly recommend Mr.Nirav for his his professionalism and result oriented approach. "

Yashaswi Consultants Founder and CEO

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