1. A manufacturer of coffee pods (like Keurig's cups) makes many different types of pods for many different customers and must therefore frequently change over the line to different pods, often several times a day. The coffee arrives already roasted, flavored, and ground in large sacks. The steps of the current changeover process occur in sequence (done by a single person) entirely at the end of the last production machine while the line is down:

i.Remove the prior runs remaining materials (labels, branded cups, branded boxes, coffee sack(s)) from the filling machine, carton filling machine, and boxing machines - 12 min

ii.Get the new run's materials (labels, cups, sacks) from storeroom - 9 min

iii.Clean out the coffee intake and filling devices to avoid flavor contamination - 9 min

iv.Setup the sacks and branded cups on the filling machine - 6 min

v.Setup the branded product cartons on the carton filling machine - 5 min

vi.Setup the new labels on boxing machine which boxes multiple product cartons into shipping boxes - 4 min

vii.Manually make adjustments to the filling machine and boxing machines for differences in coffee characteristics and carton/box sizes - 4 min

Explain what changes you would look at making to this process (and why) in line with the principles of SMED / rapid setup.