Background: Supporting a Global Pharmaceutical Packaging Operation with Complex Changeover Needs
A global pharmaceutical manufacturer operating an automated packaging line faced growing challenges in managing the change parts required for frequent product changeovers. As production demands increased, so did the number and complexity of changeover components needed to support multiple packaging configurations.
Because the operation relied on a wide range of precision change parts, ensuring these components were properly organized, stored, and quickly accessible became critical. The customer needed a structured storage approach that would support consistent changeover processes while maintaining close proximity to the packaging line.
Challenge: Improving Changeover Efficiency, Accessibility, & Organization
The customer’s primary challenge centered on optimizing how change parts were stored and accessed during production changeovers. As an automated packaging operation, downtime during changeovers directly impacts productivity and maintenance costs.
Key challenges included:
- Slow and Inefficient Changeovers – Change parts were not consistently organized or stored in a standardized system, making it difficult for operators to quickly locate the correct components during changeover events.
- Lack of Proximity to Packaging Lines – Changeover parts were not always stored close to the production equipment, creating unnecessary delays when retrieving required components.
- Need for Better Accountability and 5S Compliance – The customer required a more structured, 5S-aligned storage solution to ensure all parts were accounted for and properly organized at all times.
- Operational Inefficiencies During Maintenance – Maintenance and production teams experienced added downtime due to the time required to locate, verify, and prepare change parts for use.
Overall, the customer needed a solution that would streamline changeover processes, improve organization, and ensure change parts were always readily accessible.
Solution: Custom 3D-Engineered Storage Walls & Mobile Cart Systems
Change Parts, Inc. designed and delivered a fully customized storage solution consisting of engineered wall systems and mobile carts built for the customer’s change parts.
The solution included:
- Custom Storage Walls and Carts – Purpose-built systems designed specifically for the customer’s changeover components.
- 3D Scanning for Precision Fit – Each change part was 3D scanned to create exact cutouts and storage profiles.
- Engineered Foam and Cutout Design – Cabinet storage foam and wall inserts were shaped to match each individual component.
- On-Site Field Measurement – In-plant measurements ensured accuracy and alignment with real-world operational conditions.
- 5S-Driven Organization System – Every part was assigned a designated, clearly defined storage location to ensure accountability and consistency.
This combination of engineering precision and structured storage design created a scalable, repeatable system tailored to pharmaceutical packaging requirements.
Results: Improved Organization, Efficiency, & Changeover Performance
Following implementation of the custom storage wall and cart system, the customer experienced meaningful operational improvements across their packaging environment.
Key outcomes included:
- Improved Changeover Efficiency – Operators were able to access required change parts more quickly due to organized, close-proximity storage systems.
- Enhanced Organization and Accountability – The 5S-based layout improved visibility and ensured all change parts were properly stored and accounted for.
- Reduced Time Spent Locating Parts – Centralized, custom-fit storage significantly reduced time spent searching for or verifying changeover components.
- Improved Maintenance Workflow Efficiency – Maintenance teams benefited from clearer organization and easier access to required parts.
Overall, the system significantly improved workflow efficiency and reduced unnecessary delays associated with changeover preparation.
Conclusion: A Scalable, Engineered Change Parts Storage Solution for Pharmaceutical Packaging
By implementing custom-engineered storage walls and mobile cart systems, the customer transformed a disorganized and inefficient storage approach into a structured, 5S-aligned system designed specifically for their packaging environment.
This solution demonstrates Change Parts, Inc.’s ability to engineer highly customized storage systems that support real-world operational needs, from precision design using 3D scanning to in-plant measurement and full system implementation.
With improved organization, better accessibility, and a more efficient changeover process, the customer now has a scalable storage solution that supports ongoing production demands and future growth.
Improve Changeover Efficiency in Pharmaceutical Packaging with Custom Engineered Storage Systems
Looking to improve changeover efficiency and organization in your packaging operation?
Change Parts, Inc. designs custom storage walls and cart systems tailored to your exact change parts and production environment. With precision engineering, 3D scanning, and in-plant support, we help ensure your parts are organized, accessible, and ready when you need them.
Reduce changeover time and improve organization on your line. Get in touch today to see how a custom wall and cart system can be designed for your exact operation.
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