Setup matrix: jobs ordered for short changeovers
Group items into setup families, such as a colour, a size or a die. Type the minutes it takes to change over from one family to another. By Changeover on the scheduling board then orders a machine's jobs to spend the least time changing over.
PLANSScale only
Why it matters
Changeover is where a busy machine quietly loses hours. A dark colour after a light one, a die changed back and forth, a cleaning that could have been done once. The order that saves the time usually lives in one senior operator's head. Here you write the changeover minutes between families once, per machine or for all. One press on the scheduling board reorders a machine's open jobs so each next job is the quickest to change to. The rule stays in the system when that operator is on leave.
The problem it solves
- A machine runs black, then white, then black again, and loses an hour to cleaning each time.
- Only the senior operator knows which jobs should follow which, and the plan ignores it.
- Changeover time is lost every day but never written down anywhere.
How it works
- Your planner lists the setup families under Configuration > Setup Families: for example Light, Dark and Black, or each die.
- On each item, set its Setup Family in the Machine Changeover section.
- In Configuration > Setup Matrix, type the minutes to change from one family to another. Leave the machine empty for a rule that holds on every machine, or name a machine for its own minutes.
- On the scheduling board, press By Changeover on a machine. Its jobs not started are reordered so each next job is the quickest to change to. Then they are laid out one after another on the machine's hours.
Everything it does
Setup families
- A name, an order and a colour; families can be archived
- One family per item, on the item form (Machine Changeover)
- Items with no family count as no changeover
The matrix
- From family, to family, machine and minutes
- Machine empty: the minutes hold on every machine; a machine's own row wins over the general one
- One row per machine and pair; a second is refused
- Edit as a list or see as a pivot (from down, to across)
- From a family to the same family: no changeover; a pair not in the matrix counts as 0 minutes
Ordering the jobs (By Changeover)
- Works on one machine's jobs not started
- The job first in line stays first; then each next job is the one quickest to change to from the last
- On a tie, the job whose order is due first goes first
- With fewer than three jobs the order is kept
- The jobs are then laid out one after another on the machine's free hours
Families that work well
- Colours on a dyeing or moulding machine: Light, Medium, Dark, Black; light to dark is quick, dark to light needs a wash
- Dies or moulds on a press: one family per die, so jobs on the same die run together
- Sizes or materials on a cutting or forming machine: one family per thickness or grade
Who uses it
PlannerKeeps the families and the changeover minutes, and presses By Changeover on the board.
Manufacturing AdministratorSets the family on each item.
SupervisorTells the planner the real changeover minutes from the floor.
Where you use it
- Web: Manufacturing > Configuration > Setup Families and Setup Matrix
- Web: the item form, Machine Changeover section
- Web: Manufacturing > Planning > Scheduling Board, By Changeover on each machine
- Not in the SmartMy Manufacturing app (built and in testing, not in the app stores yet): this screen is on the web
What you control
Settings
- Families and their order: none to start with
- Changeover minutes per pair, for every machine or one machine: none to start with (0 minutes)
Questions
Does the board add the changeover minutes to the schedule?
No. The matrix decides the order of the jobs. The jobs are then laid out on the machine's hours with their own expected minutes. Put setup time on the step if you want it planned.Can one machine have different minutes from the rest?
Yes. Add a row with that machine named. It wins over the row with no machine for the same pair.Does it reorder every machine at once?
No. By Changeover works on one machine at a time, from the scheduling board.Can a late job be pushed back by the reordering?
It can. The first job keeps its place, and ties go to the order due first, but the order follows the changeover minutes. Check the red late bars after you reorder.Where do the changeover minutes come from?
From you. Ask the operators how long each change really takes, type it once, and correct it as you learn. Pairs you leave out count as no changeover.Which plan has the setup matrix?
Scale, with the scheduling board.Related features
LINES AND SCHEDULINGScheduling board: jobs across machines and daysEvery machine is a row and every day a column, with each job as a bar. Drag a job to move it in time or to an allowed machine. See each day's load against the machine's hours, and replan a machine in one click.LINES AND SCHEDULINGMaster schedule and rough-cut capacityBuild a week-by-week plan of what to make for each item and plant from your forecasts, customer orders and stock. Change the plan where you know better, firm the sure weeks into production orders, and check the load on each machine before you commit.LINES AND SCHEDULINGOEE per machine and day, and the machine board on a TVOEE is worked out every hour for each machine and day from its running time and the pieces counted at the terminal. It is split into availability, performance and quality. A machine board on a TV shows every machine as working, stopped or idle.PRODUCTION AND JOB WORKBills of materials, production orders and work ordersKeep each item's bill of materials with its components and the steps on your machines. A production order reserves the material, lays out the work orders step by step and puts the finished goods into stock at cost.LINES AND SCHEDULINGAssembly lines: operation bulletins, balancing and hourly outputSet up each line with its stations, and write an operation bulletin per item with the SMV of every step. See the bottleneck and line balance at once. Each day's line plan becomes a production order, and the hourly board fills from the shop floor terminal.
See your shop floor on it.
Tell us what you make, how many machines and people you run, and how production is recorded today. We will set up a line with you and run a job on the terminal.