🇦🇺Australia

Waste from Changeovers

1 verified sources

Definition

Poor scheduling causes prolonged changeovers, leading to material scrap and inefficient resource use in flexible packaging production.

Key Findings

  • Financial Impact: AUD 20,000-100,000/year in waste (2-5% of material costs for mid-size firm)
  • Frequency: Per production run
  • Root Cause: Manual scheduling without optimization tools

Why This Matters

The Pitch: Packaging players in Australia waste AUD 50,000+ annually on changeover waste. Automation of scheduling optimizes setups and eliminates this loss.

Affected Stakeholders

Production Manager, Scheduler

Deep Analysis (Premium)

Financial Impact

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Current Workarounds

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Methodology & Sources

Data collected via OSINT from regulatory filings, industry audits, and verified case studies.

Evidence Sources:

Related Business Risks

Excessive Overtime

AUD 40 hours/month overtime at AUD 50/hr = AUD 24,000/year

Idle Equipment Bottlenecks

AUD 50,000-200,000/year (10-20% capacity loss)

Cost of Poor Quality

AUD 10,000-50,000 per new colour project (6-8 weeks delay, scrap, rework); 2-5% production waste from mismatches[1][3][4]

Capacity Loss

AUD 5,000-10,000/week equipment idle (6-8 weeks per match); 20-40 hours/month manual delays[1][5]

Cost Overrun

AUD 2,000-5,000 per colour (test prints, pigments, pellets); 1-3% ink/supply waste[1][5][4]

Produktivitäts- und Kapazitätsverlust durch manuelles Artwork-Versionieren

Quantified (Logic): ca. 250–1.000 Stunden unnötiger manueller Koordination p.a. ≙ AUD 15,000–100,000 Kapazitätskosten pro Jahr für einen mittelgroßen Hersteller.

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