40% Faster Line Changeover for a European Packaging OEM

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.