Reduce downtime with AR guided changeover procedures

The problem: complex, error-prone changeovers cost time and money

Changeovers are among the highest-impact activities in manufacturing operations. Every minute a line is down for changeover is a minute of lost production. Yet changeovers are also one of the most error-prone processes—settings are missed, steps are skipped and small mistakes cascade into startup problems that extend downtime further. The challenge grows as product portfolios expand and batch sizes shrink.

• Machine changeovers are time-consuming and rely on a small group of experienced specialists who know the nuances of each transition
• Settings, checks and adjustments are not always fully documented, leaving room for variation and error
• Small mistakes during changeover lead to startup defects, scrap and extended downtime in the next batch
• OEMs and field service partners have limited visibility into how changeovers are actually performed, making support and optimisation difficult
• Knowledge of best practices is concentrated in a few hero operators—when they are unavailable, changeover times balloon
• High product mix and frequent changeovers multiply the risk of error and inconsistency

For operations leaders, changeover performance directly impacts OEE, throughput and cost. Reducing changeover time and eliminating errors is a proven lever for improving manufacturing competitiveness—but achieving consistency at scale requires more than better documentation.

How AI and AR–guided work instructions solve this

AR-guided changeover procedures bring standardised, visual guidance directly to the operator at the machine. Instead of consulting binders, relying on memory or asking a colleague, operators see exactly what to do, where to do it and in which order—overlaid on the actual equipment. AI-powered verification ensures critical steps are completed correctly, and remote expert support is available instantly when needed.

1. The previous batch is completed and the line is ready for changeover.
2. The operator scans a batch code or selects the next product in the AR system.
3. The system automatically loads the specific AR changeover procedure for that batch, product or configuration.
4. In the field of view—via smart glasses or tablet—the operator sees numbered, visual instructions in their preferred language.
5. For critical settings and checks, the system prompts the operator to confirm completion or captures evidence via photo or video.
6. If the system or operator detects a deviation, a remote expert session can be started instantly for guidance.
7. After the final check, the AR system confirms that the machine is ready for production and logs the changeover as complete.
8. All steps, timestamps and evidence are stored in a digital logbook for analysis, audits and continuous improvement.

This step-by-step, verified approach reduces changeover variability, prevents errors and shortens transition times—regardless of which operator is on shift.

Who is this for?

AR-guided changeover and batch preparation is relevant for a wide range of roles focused on operational efficiency and quality:

• Operations managers who need to reduce changeover time, improve OEE and minimise unplanned downtime
• Production planners responsible for scheduling changeovers and managing batch transitions across multiple lines
• Maintenance managers who see the link between correct changeover execution and equipment reliability
• Quality managers focused on reducing startup defects and First Time Right issues after changeovers
• Continuous improvement leaders driving lean and SMED initiatives to standardise and accelerate changeovers
• Plant managers and site directors looking to improve throughput and reduce the hidden costs of slow or inconsistent changeovers

Where is this used?

AR-guided changeover and batch preparation is deployed across industries where frequent changeovers, high product mix or strict quality requirements make consistency critical:

• Food and beverage, where frequent product and flavour changes require fast, reliable changeovers to maximise line utilisation
• Pharmaceutical and life sciences, where batch-to-batch transitions must be documented, validated and compliant with GMP requirements
• Packaging and filling, where high-speed lines and frequent format changes demand precise setup procedures
• Automotive and industrial equipment, where high-mix production and customer-specific configurations require accurate changeover execution
• Chemicals and specialty materials, where process settings and cleaning steps are critical to product quality and safety
• Consumer goods, where seasonal and promotional product runs create frequent changeover cycles

Typical process and workflow

Implementing AR-guided changeovers typically follows a structured workflow that integrates with your existing production planning and execution systems:

1. Identify critical changeover types: Work with operations, planning and quality teams to list the changeovers that are most frequent, longest or most error-prone.
2. Document best-practice procedures: Capture the sequence, settings, checks and tips used by your most experienced operators. Involve subject matter experts in defining the standard.
3. Convert to AR format: Translate changeover procedures into interactive AR content with visual cues, checkpoints and variant logic. Include language options for multilingual teams.
4. Integrate with production systems: Connect the AR changeover platform with your MES, ERP or scheduling system to pull batch data and log results automatically.
5. Pilot and validate: Roll out AR-guided changeovers on selected lines. Measure changeover time, First Time Right and operator feedback. Refine content based on real-world use.
6. Scale and standardise: Expand AR-guided changeovers to additional lines, products and sites. Use templates and governance to ensure consistent rollout.
7. Continuously improve: Use data from AR-logged changeovers to identify bottlenecks, optimise steps and drive ongoing improvement.

Concrete examples and mini-scenarios

AR-guided changeovers deliver measurable results in a variety of real-world scenarios:

Scenario 1: Packaging line format change in food manufacturing. A food manufacturer runs multiple product formats on the same packaging line. Changeover times vary widely depending on who performs them. AR work instructions standardise the sequence, highlight adjustment points and verify critical settings. Changeover time drops by 25% and startup defects are cut in half.

Scenario 2: Batch-to-batch transition in pharma. A pharmaceutical company must document every changeover step for GMP compliance. AR-guided procedures capture timestamps, operator confirmations and photos for each step. Auditors receive clear, traceable evidence of compliant execution—reducing audit preparation time and risk.

Scenario 3: High-mix CNC setup in industrial equipment. A job shop faces long setup times and frequent errors when changing over CNC machines for custom orders. AR SOPs guide operators through tool changes, fixture setup and programme selection. Setup time falls by 30% and scrap from incorrect settings drops sharply.

Getting started with AR-guided changeovers

If you are considering AR-guided changeover procedures, here is practical guidance to get started:

• Prerequisites: Identify the changeovers that are most frequent, longest or most error-prone. Ensure you have access to subject matter experts who can define best-practice procedures.
• Pilot scope: Start with 2–5 changeover types on a selected line or area. Focus on changeovers with clear steps and measurable outcomes.
• KPIs to track: Changeover time, First Time Right rate at startup, downtime due to changeover errors, scrap from incorrect settings and operator feedback.
• Devices: AR-guided changeovers can run on smart glasses, tablets or smartphones. Smart glasses offer hands-free guidance for operators working on equipment.
• Change management: Involve operators, supervisors and planning teams early. Demonstrate quick wins and address concerns about pace and accountability transparently.

FAQ: AR-guided changeover and setup reduction

How much can AR-guided changeovers reduce changeover time? Most organisations see 15–40% reduction in changeover time, depending on baseline variability and process complexity.

Can AR changeover procedures adapt to different product variants? Yes. Modern AR platforms support variant logic, loading the correct procedure based on batch code, product type or configuration.

How does remote expert support work during a changeover? If the operator encounters an issue, they can start a live video session with a remote expert. The expert sees what the operator sees and can add annotations, highlights and spoken guidance in real time.

What if our changeover procedures are not fully documented? AR content creation can serve as the documentation process itself. As experts perform changeovers, the system captures steps, images and notes—building the SOP as the work is done.

How does AR-guided changeover support lean and SMED initiatives? AR work instructions standardise internal and external setup activities, reduce search time and ensure consistency—key principles of SMED (Single-Minute Exchange of Die) methodology.

Next steps

Ready to reduce changeover time, eliminate errors and improve OEE with AR-guided changeover procedures? ActARion helps manufacturers standardise and accelerate changeovers using AI and AR–guided work instructions.

Schedule a discovery call to discuss your changeover challenges and see how AR-guided procedures can fit your production environment. No commitment—just a practical conversation about what is possible.

Further reading

Explore related articles to learn more about this use case:

• AR-guided changeovers: a practical playbook to reduce downtime
• Capturing best-practice changeover sequences with AR SOPs
• From 'hero operators' to standardised changeovers with digital work instructions
• How to pilot AR work instructions on a critical changeover