Applications / Operations Intelligence
Changeover Verification
Times every changeover from last-good to first-good, detects the steps performed inside it, and flags missed line-clearance and cleaning actions.
See it in action
A forty-minute changeover with fourteen minutes of waiting
Video slot — awaiting upload.
What it detects
Changeover is the most repeatable loss on the line and the least measured. Fogsphere times it end to end, and shows what happened inside the gap.
Changeover start and end detection
Detects the start and end of each changeover, producing a measured duration for every one.
Crew, tool and material arrival
Times when the changeover crew, the tooling and the first material actually arrive at the line.
Cleaning and fixture changes
Detects cleaning, fixture changes, setup actions and repeated adjustments inside the changeover window.
Line clearance verification
Confirms line clearance between runs — that the previous product, packaging and labels have been removed.
Batch and line changeover activity
Logs batch and line changeover activity as a timestamped sequence rather than a single duration.
Cleaning sequence and completion
Checks that the cleaning sequence ran in order, and that washdown and foam application completed.
Residual objects and materials
Flags residual objects, materials and cleaning equipment left in the area at restart.
Personnel present during cleaning
Detects whether the required personnel were present for the cleaning and clearance steps.
Restart before sanitation completes
Flags a restart that begins before the sanitation or clearance steps have finished.
Wrong tool or wrong area
Detects a wrong tool used, or a step performed in the wrong area, against the standard sequence.
Changeover and cleaning downtime
Reports changeover and cleaning downtime as its own category, separated from unplanned stops.
Where it applies
Changeover exists wherever a line runs more than one product. The Q3 papers describe it as both a lost-time problem and an evidence problem, and the same detections serve both.
How it works
Edge inference on the cameras you already have
Changeover step detection runs on the edge device next to the cameras already covering the line and its approach. The sequence is read from what happens in frame, not from a checkbox filled in afterwards.
Zones, thresholds and schedules you configure
Define the changeover window, the steps expected inside it, and the order they should run in. Each product family, line and clean type can carry its own sequence and thresholds.
Every event carries its own evidence
Each detection is logged with a timestamp, the camera and zone it came from, and a short clip. The record can be reviewed, exported or attached to an investigation without trawling through hours of footage.
Feeds the systems already in place
Events surface in Fogsphere Manager and route outward to the MES, quality system, HACCP record, shift-report pack or messaging channel operators already watch.
Risk & control objective
The control objective is a changeover that is both fast and complete. Those two pull against each other, and the record usually captures neither — a start time, an end time and a signature.
The value is in seeing inside the window. A forty-minute changeover made of fourteen minutes waiting for tooling is a scheduling problem; the same forty minutes made of repeated adjustment is an engineering one. The duration alone does not distinguish them.
For food, pharmaceutical and chemical lines the same detections carry a second purpose. Line clearance, cleaning completion and residual-material checks are evidence obligations, and a visual record with timestamps is what an audit asks to see.
Related solutions
Time the changeover, and see what happened inside it
We will show you changeover timing, step-sequence detection and line-clearance evidence on your own camera estate.