America's Only Dedicated Changeover Specialist
Generalist lean consultants treat changeover as one item on a checklist. We treat it as the entire engagement — and the results show it.
Every time one of your lines stops to change over, you're not just losing minutes. You're losing capacity you've already paid for.
A VP of Manufacturing at a major global pharmaceutical company called us during Covid-19 vaccine production. We were already committed to another client. He said: "Do you want to make water cheaper, or do you want to save lives?" We rescheduled the other engagement and drove cross-country to his plant. We increased throughput more than 14%. Every percentage point meant more vaccines, faster.
A VP of Manufacturing at a major global pharmaceutical company called us during Covid-19 vaccine production. We were already committed to another client. He said: "Do you want to make water cheaper, or do you want to save lives?" We rescheduled the other engagement and drove cross-country to his plant. We increased throughput more than 14%. Every percentage point meant more vaccines, faster.
What We Do
There are thousands of lean consultants in the United States. Most will arrive with a checklist that includes changeover, 5S, value stream mapping, and twelve other initiatives. We arrive with one question: what is your changeover costing you?That singular focus is why our results look different.
Results That Speak to a VP
Pharma — Critical pandemic-era production ramp-up
A major global pharmaceutical manufacturer needed more output under impossible pressure. We increased throughput 14% by eliminating changeover waste. No new lines. No new shifts. Just faster, more reliable changeovers.
Food & Beverage — 22 Million More Cans Per Year
A major soft drink bottler runs 3–5 changeovers daily on a canning line producing 1,500 cans per minute. We trimmed 15 minutes from each changeover. That's one extra hour of runtime every day — 250 hours per year — and 22 million additional cans of capacity. No new equipment. No new staff. Just faster changeovers.
Medical Devices — 7.5 FTE of Recovered Productivity
At a medical device manufacturer's production facility, we installed Vorne production monitors across 30 work cells. The efficiency gains in production flow were significant — but the hidden win was time. In each 5-person cell, one team member was spending 25% of their working day manually maintaining a whiteboard with production metrics. The Vorne system automated that entirely. Multiply that across 30 cells and you've recovered the equivalent of 7–8 full-time employees' worth of productive time — while giving the department manager real-time data instead of an hourly clipboard round.
Find Out What Your Changeovers Are Costing You
Most plants don't know what their changeovers are really costing them. That's usually the first thing we fix. Use our free Changeover Loss Calculator to find out — then let's talk.
How We Work With You
Changeover Assessments — We come onsite, observe, measure, and deliver a clear picture of where you're losing time and capacity.
Training Skillshops — Hands-on training that turns your team into changeover problem-solvers, not just followers of a new procedure.
Kaizen & Coaching — Ongoing support as your team implements changes and drives continuous improvement.
Vorne Monitor Installation & Training — We program, install, and train your team on Vorne OEE monitors, turning real-time data into real decisions.
Technical Writing — Standard operating procedures, changeover documentation, and training materials that actually get used.
Ready to Recover Lost Capacity?
You don't need a new machine. You don't need more headcount. You need faster changeovers — and that's all we do.
John Henry | The Changeover Wizard 📞 1-787-550-9650 ✉️ johnhenry@changeover.com