40% Faster Line Changeover for a European Packaging OEM
Packaging Machinery OEM (EU)
Redesigned the drive package of a packaging line and cut changeover time by 40% using plug-and-play motor-gearbox units.
Measured outcomes
- -40%
- Changeover time reduction
- -60%
- Field failure reduction
- 28 days
- Order lead time
- 3,500+
- Units supplied / year
Measured for Packaging Machinery OEM (EU). Results vary by application and specification.
Challenge
The OEM's packaging line used separate motor and gearbox sourcing, causing long changeover times and mixed quality.
Solution
We supplied pre-assembled motor-gearbox units with consistent shaft dimensions and color-coded connectors, plus a small standard parts library.
Result
Line changeover dropped from 45 to 27 minutes. Field failure rate fell by 60% in the first year.
The customer is a German packaging machinery OEM with a global install base. Their biggest complaint from end users was slow changeover between product formats, and inconsistent drive quality from multi-supplier sourcing.
The challenge
Each line was built from separately sourced motors and gearboxes. Tolerances varied, connectors were not standardized, and changeover required tooling and adjustment.
Our approach
We worked with the OEM’s engineers to standardize the drive package:
- Pre-assembled motor-gearbox units with one torque spec per station
- Standardized shaft and flange dimensions across the range
- Color-coded connectors and a shared spare parts library
- Full test reports shipped with every batch
The result
Changeover time fell by 40%. The OEM simplified their inventory from 40 SKUs to 12, and field failure rates dropped by 60% in the first year of supply.