Frequent SKU changeovers. Lines running 24/7. A workforce that turns over faster than your procedures change. Retailer audits that keep raising the bar. You need speed and consistency at the same time.
Multiple SKU switches per shift. Each one has its own quality parameters, packaging specs, and label requirements. The margin for error is thin, and every changeover is a risk for mix-ups.
New operators every few months. Seasonal peaks. Temp workers cycling in and out. The onboarding quality depends on which shift they land on and who happens to mentor them.
Every retailer raises the bar. BRC, IFS, retailer-specific requirements. You need to demonstrate traceability, training compliance, and procedural adherence at any moment, not just during scheduled audits.
Every unplanned stop costs production volume. Reason codes are captured inconsistently. The top loss drivers aren't visible until the monthly report. By then, you've lost four weeks of potential improvement.
Structured changeover procedures per product and line combination. Mandatory checks before production restarts: correct label, correct packaging material, correct parameters. Photo evidence for label and packaging verification. Sign-off required before the line runs. Every changeover documented with full context for traceability.
"We cut changeover errors by 70% in the first quarter. Not because our people changed. Because the process is now enforced, not just documented."Production Manager, CPG Manufacturing
Weight, dimensions, visual quality, and seal integrity verified at defined intervals. Out-of-spec values flag immediately and create a quality issue with full production context: line, product, batch, reading. Retailer or consumer complaints trigger an investigation linked to production data, batch records, and quality checks. Root cause analysis structured. Corrective actions tracked to closure.
Every SKU switch follows the same structured process. No shortcuts. No guesswork. Traceable from start to finish.
Last batch finished. The operator opens the changeover checklist in Maecos. It loads automatically for this specific product-to-product transition on Line 3.
All materials, labels, and products from the previous run verified removed. Photo evidence captured at each station. Allergen residue check if applicable. Mandatory sign-off before proceeding.
New packaging materials, labels, and raw materials staged and verified against the production order. Barcode scan confirms correct materials. Label language and allergen declaration checked with photo capture.
Machine settings adjusted for the new SKU. Fill weight, seal temperature, conveyor speed. Each parameter verified against the approved specification. Deviations flagged before the line starts.
First units off the line checked against all quality parameters: weight, seal, label, appearance. Approved before full-speed production begins. The changeover checklist closes with total time and compliance status recorded.
Structured learning paths for every role. Seasonal and temp workers get shorter paths covering essential safety and quality modules. Qualifications tracked with the same rigor as permanent staff. Access gated by completion. When operators return next season, their previous progress is preserved. No re-doing modules they've already passed.
"We onboard 80 seasonal workers every summer. With Maecos, they reach qualified status in three weeks instead of six. And we can prove it to auditors."HR Manager, Consumer Goods
“We run 12 SKU changes per shift on our fastest line. Before Maecos, changeover compliance was aspirational. Now it's enforced. Every changeover is documented, every label is verified, and our retailer audit scores reflect it.”Operations Manager, European CPG Manufacturer
Multi-line CPG facility. 200+ operators. 40+ SKU changes per day.
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