Setup time is a crucial aspect of manufacturing that, if not properly accounted for, can lead to inefficiencies, delays, and even missed delivery deadlines. This is particularly relevant in the make-to-order sector, where production processes are geared towards specific customer orders and efficiency is crucial for on-time delivery. In this article, we’ll dive into why setup times are essential to consider when scheduling and how manufacturers can effectively incorporate them into their operations for smoother production processes.
Why setup times matter
Setup times are the intervals required to prepare equipment, tools, or machines for production. This can include changing machine settings, cleaning, or switching materials. While it might seem like a minor detail, overlooking setup time can lead to significant production bottlenecks. For example, in an operation involving a painting line, switching between different colours may require thorough cleaning of equipment between batches. This can take anywhere from a few minutes to several hours, depending on the colour combination. Not accounting for this time can lead to overlap in production schedules, creating chaos on the shop floor.
The consequences of neglecting setup times extend beyond the immediate production schedule. Downstream processes may also be impacted, leading to disruptions in the overall workflow. In complex manufacturing environments, where multiple machines are linked to form a continuous production process, a delay in one stage can halt the entire line. In addition, it can cause challenges in inventory management, where stock is either overproduced or underproduced due to scheduling issues.
How setup times impact Scheduling: An example
Let’s look at a practical example. Imagine a manufacturer that uses a laser drilling machine, which is responsible for drilling precise holes in metal sheets. In this scenario, setup times are influenced by the diameter of the holes that need to be drilled. Smaller diameters require more precise calibration and testing, which increases setup time.
For instance, if the setup involves drilling a 1 mm hole after drilling a 3 mm hole, it might take 480 minutes to adjust the machine and ensure it is functioning accurately. Conversely, moving from a 3 mm to a 2 mm hole may only take half the time, around 240 minutes. If these setup times aren’t factored into the scheduling process, the production flow may be severely impacted, leading to idle time and inefficient machine usage.
By understanding and mapping these setup times into the scheduling system, the manufacturer can optimize the sequence of production orders. For example, scheduling the smaller diameter holes first and progressing toward larger diameters can reduce setup time, as the larger holes are easier and faster to drill. This strategic scheduling can create buffers in the production timeline and prevent cascading delays.
How to incorporate setup times into Scheduling
- Standard setup time and exceptions: One way to manage setup times effectively is by setting a standard time for each machine or process. For example, you might set a standard of 45 minutes for cleaning a painting line, regardless of the colour changes. However, exceptions should be defined for scenarios that require more time. For instance, switching from black to yellow might take five hours, while going from orange to yellow might only take one hour. By defining these exceptions, manufacturers can maintain accurate schedules that account for the intricacies of different processes.
- Master data and item attributes: Organizing production data with item attributes that drive setup times is another effective strategy. For example, in the case of the laser drilling machine, the attribute driving the setup time is the diameter of the hole. By incorporating this information into the scheduling system, manufacturers can automatically adjust the setup times based on the characteristics of the production order. This approach ensures that the correct setup times are accounted for without manual intervention, streamlining the scheduling process.
- Pre-sorting production orders: A practical method to reduce setup time is to pre-sort production orders in a way that minimizes the need for equipment adjustments. For example, grouping orders with similar attributes (such as colour in a painting process or diameter in a drilling process) reduces the need for frequent machine recalibrations. This method, often known as “campaign scheduling,” optimizes machine usage and reduces downtime caused by setups.
Use Case: Painting Line Setup
Let’s consider a painting line that produces products in various colours. In this case, the manufacturer faces setup times due to cleaning requirements when switching colours. The standard cleaning time is set at 45 minutes, but this time can vary depending on the specific colour change. For instance, switching from yellow to yellow requires no cleaning, whereas going from black to yellow might take five hours. By predefining these values and incorporating them into the production schedule, the manufacturer can create a more realistic timeline and avoid last-minute delays due to setup processes.
Moreover, grouping orders by colour can further optimize the schedule. For example, instead of alternating between yellow and black, the manufacturer could complete all yellow products before moving on to black products, reducing the number of cleanings required.
Conclusion
Incorporating setup times into scheduling is essential for efficient manufacturing operations. It ensures that production flows smoothly and reduces downtime, allowing manufacturers to meet their deadlines and produce high-quality products. By using standard setup times, defining exceptions, organizing production data with item attributes, and leveraging advanced planning systems such as Netronic Manufacturing’s Schedule (VAPS), manufacturers can effectively manage setup times and optimize their schedules. Ultimately, careful consideration of setup times leads to improved efficiency, higher output, and better customer satisfaction.
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