Manufacturers in machine‑heavy environments and job shops face similar and recurring challenges when trying to create flow. This is caused by limited knowledge of and access to proper methods and tools, the use of improper approaches, a lack of data, and the use of fragmented spreadsheets. This typically results in variability, unbalanced WIP, poor flexibility, and long lead times. Typical shop floor challenges include:

• oversized and inconsistent lot sizes, even for the same part number
• long, unstable and unpredictable changeovers
• breaking up of setup routines and product runs to accomodate rush orders
• unbalanced WIP across part numbers
• long and variable run lengths on equipment, limiting flexibility
• insufficient insight into machine and setter load

Engineering and management teams face their own constraints:

• limited visibility into actual changeover frequency and duration
• missing or fragmented data across machines, products, and shifts
• difficulty modelling EPEI, lot sizes, and product mix in Excel (if even done at all)
• misalignment between engineers, managers, and operators
• slow scenario evaluation when mix, demand, or capacity changes
• enterprise systems that do not accomodate C/O, EPEI and SMED analysis

The above creates a strong need for a structured, realistic, and accessible environment for analysing changeovers, evaluating EPEI, modelling lot sizes, and improving flow in machine‑heavy operations.

The MCE Suite provides a complete, structured environment for analysing changeovers, modelling lot sizes, evaluating EPEI, and improving flow in machine‑heavy operations. Its modular architecture supports scalable adoption and enables teams to work concurrently across machines, products, setters, and changeover data. The system consists of interconnected modules that together form a comprehensive workflow:

• Master Data — defines calendars, volume units, time periods, and team and shift structures for consistent use across environments
• Machines — models machines and equipment and machine types, enabling analysis of machine capacity, run times, changeover times, rejects, and machine‑level EPEI (current, as well as cycle‑based and factor‑based EPEI strategies)
• Products — defines products, their required numbers, value, and lot sizes, product families, setup groups, and product‑machine allocations, supporting evaluation of product‑level EPEI (current, as well as cycle‑based and factor‑based EPEI strategies)
• Setters — defines setters and setter teams, enabling analysis of setter workload, and setter‑driven bottlenecks in various scenarios
• Changeovers — defines changeover standards and the changeover matrix, logs actual changeovers, and supports analysis of actual daily changeovers and changeover duration, C/O matrix actuals, actual product EPEI, actual scaled machine EPEI, and the setting of EPEI-aligned SMED targets

This modular system ensures consistency, scalability, and efficient teamwork across the entire changeover, EPEI, and flow‑improvement process.

MCE Suite differentiates itself through a unique combination of analytical depth, operational realism, and Excel‑native accessibility. It provides engineering‑grade modelling without the cost, rigidity, or overhead of enterprise systems, while avoiding the fragility and inconsistency of traditional spreadsheets. Key differentiators include:

• Excel‑native architecture — advanced modelling without new software, IT involvement, or complex onboarding
• Integrated workflow — machines, products, setters, changeovers, EPEI and SMED in one structured environment
• Realistic modelling — actual changeover durations, rejects, machine capacity, and setter availability
• EPEI‑driven analysis — current, cycle‑based, and factor‑based EPEI at both product and machine level
• SMED target evaluation — required changeover times derived directly from EPEI goals and setter capacity
• Modular design — five interconnected modules supporting clear workflow and parallel teamwork
• Dynamic reporting — print‑ready charts and dashboards for clear communication and rapid alignment
• Low cost of ownership — enterprise‑grade capability at a fraction of the cost and complexity
• Rapid deployment — minimal installation, no integration, and limited training requirements
• Consistency and traceability — standardised workflow for repeatable, auditable decisions

These differentiators position MCE Suite as a robust and uniquely complete solution, delivering changeover‑, EPEI‑, and lot‑size‑driven insights that simply do not exist in today’s ERP, MES, APS, or OEE platforms.