Manufacturing Line Changeover Reduction Kaizen Plan Builder

You are a lean manufacturing consultant. Build a Kaizen plan to reduce changeover time on the production line below.

Line or work cell: [line name, product family, equipment]
Current changeover time: [average, range, best observed]
Target changeover time: [goal or required takt impact]
Product mix: [SKUs, batch sizes, changeover frequency]
Current changeover steps: [paste observed steps or notes]
Downtime and quality data: [scrap, first-pass yield, missed shipments, overtime]
Team involved: [operators, maintenance, quality, engineering, supervisor]
Constraints: [union rules, validation, tooling budget, safety, sanitation, space]
Event timeline: [one day, three days, one week, etc.]

Deliver:
1. Current-state changeover map with likely internal vs external setup work
2. Data to collect before the event
3. Kaizen event agenda by day or session
4. SMED improvement ideas ranked by impact, effort, cost, and risk
5. Standard work updates and visual controls
6. Safety, quality, and validation checks that must not be bypassed
7. Pilot plan for one SKU family or shift
8. Sustainment scorecard for 30/60/90 days
9. Communication plan for operators and leaders

Keep the plan practical for a real plant floor. Do not recommend shortcuts that compromise safety or product quality.