Bottling Line A — Changeover Procedure: 500 ml to 1L

Changeover Summary

Required Tools & Materials

• [ ] 1L bottle change parts kit (CP-1000R): filler nozzles, guide rails, cap chute
• [ ] Allen key set (3 mm, 5 mm, 6 mm)
• [ ] Torque wrench (10–50 Nm range)
• [ ] 1L bottles (minimum 200 for startup and first-article inspection)
• [ ] 1L caps, labels, and shrink bands
• [ ] Sanitizer solution for filler rinse

Line Clearance

1. Stop the line and allow all in-process bottles to complete
2. Remove all remaining 500 ml bottles, caps, and labels from the line
3. Physically verify no 500 ml materials remain on infeed conveyors, hopper, or labeler magazine
4. Wipe down the filler bowl and nozzles with sanitizer
5. Sign the Line Clearance form (F-PRD-021) — both technician and operator

Mechanical Setup

1. Filler: Swap nozzle set from 500 ml (green band) to 1L (blue band). Torque to 25 Nm.
2. Guide Rails: Adjust infeed and outfeed rails to 90 mm width using the scale markings. Lock thumbscrews.
3. Cap Chute: Replace the 28 mm chute with the 38 mm chute. Verify caps feed smoothly.
4. Labeler: Load 1L label roll. Adjust label placement sensor to 145 mm from base.
5. Shrink Tunnel: No mechanical change required.
6. Case Packer: Adjust lane dividers for 1L 12-pack configuration.

Parameter Settings

First Article Inspection

Run 10 bottles through the complete line. Inspect:

• [ ] Fill volume: Weigh 5 bottles — target 1,005 ml +/- 5 ml
• [ ] Cap torque: Test 5 bottles — target 18 in-lb +/- 2 in-lb
• [ ] Label placement: Verify position, alignment, and adhesion on all 10
• [ ] Shrink band: Fully seated, no wrinkles, tamper-evident bridge intact
• [ ] Date code: Correct date, lot number, and legibility

Production Release

• First article inspection PASS: All checks within specification
• Quality Technician sign-off on form F-QA-030
• Enter new SKU in the production tracking system (MES terminal)
• Begin full-speed production