33% faster changeovers: how FactoryPal granted 9+ productive hours per month with AI

Changeovers are a fact of life in manufacturing — especially in high-mix environments like tissue production. But what happens when they become a serious drag on performance?

For one leading tissue producer, frequent product changeovers were eating into valuable production time. Manual adjustments, shift-to-shift inconsistencies, and a lack of real-time guidance meant that each changeover could take as long as 28 minutes — time that added up fast across the month. And with growing demand for product variety, this downtime became a limiting factor for both capacity and flexibility.

Instead of investing in new machines, the manufacturer partnered with FactoryPal to unlock hidden capacity by optimizing their changeover process using AI.

FactoryPal’s solution eliminated the need for trial-and-error setups. Operators received intelligent, real-time recommendations tailored to each product-line combination — allowing them to execute changeovers faster, more consistently, and with less reliance on experience or shift-specific know-how.

What began as a production pain point soon became a competitive advantage.

To overcome these challenges, FactoryPal implemented its AI-powered, closed-loop optimization system. Over a 30-day diagnostic period, the system captured performance data across shifts, helping uncover performance losses that had previously gone unnoticed.

By analyzing this data, the AI identified a stable speed that the line could sustain more consistently. Key machine parameters were then optimized to support this target speed. Operators were equipped with real-time, shift-specific recommendations — integrated directly into their workflow — helping them make confident, data-driven decisions on the shop floor.

Importantly, the system continued learning and adapting to evolving production conditions, ensuring that improvements were not just one-off gains, but part of a sustainable shift in performance.

Reducing changeover downtime does more than just save time — it boosts agility, increases equipment utilization, and opens the door for a broader product mix without impacting output. The result? Higher OEE, more flexibility, and a measurable business impact.

Want the full picture?

Find out how much downtime was cut, how many hours of productive capacity were unlocked per month, and how FactoryPal helped this manufacturer scale operational best practices across shifts?

Download the full customer case to see the complete performance metrics and the exact steps FactoryPal used to help this manufacturer unlock the full potential of its production line.