Home
Why Changeover Timing Matters
Lean Manufacturing
What Is Scheduling Software
Modeling Setup Time
Benefits
Conclusion
Manufacturing scheduling software plays a critical role in improving production efficiency, especially when it comes to managing machine changeovers. Whether you’re dealing with setup time, make-ready time, or clean-up time, the goal is the same: minimize downtime and maximize output.
In this post, we’ll explore how advanced production scheduling software helps manufacturers reduce costs, improve delivery performance, and make smarter decisions about changeovers.
Why Changeover Timing Matters in Manufacturing
Poorly timed changeovers can wreak havoc on your production line:
- Too many changeovers too soon: Reduces efficiency and increases operational costs
- Too few changeovers too late: Leads to missed delivery deadlines and poor customer service
Regardless of your terminology—setup time, changeover time, or machine downtime—when your equipment isn’t producing, you’re losing money.
Can Lean Manufacturing Reduce Setup Time?
Lean manufacturing techniques are effective at reducing changeover time, especially in repetitive production environments with stable demand. But if your operation resembles a job shop with fluctuating demand across many item numbers, traditional Lean methods may not be enough.
In such cases, investing in manufacturing scheduling software can deliver better results.
What Is Manufacturing Scheduling Software?
Also known as:
- Production scheduling software
- Advanced planning and scheduling (APS) software
This technology helps manufacturers:
- Calculate setup times between different item numbers
- Schedule changeovers at optimal times
- Balance cost efficiency with on-time delivery
Two Methods for Modeling Setup Time in Scheduling Software
To accurately schedule changeovers, the software needs setup time data. There are two main approaches:
1. Matrix-Based Setup Times
Users provide a matrix that specifies setup durations for each item-to-item transition. This method is simple and works well when setup times are consistent.
2. Attribute-Based Setup Penalties
Each item is assigned attributes (e.g., material type, mold, color). The software calculates setup time based on changes in these attributes.
Example: Injection Molding
- Changing the plastic resin = 1 hour setup
- Changing the mold = 1 additional hour
If both change, the software schedules a 2-hour setup. If only the resin changes, it schedules just 1 hour. This method offers greater flexibility and precision.
Benefits of Using Manufacturing Scheduling Software
Implementing advanced scheduling software helps manufacturers:
- Reduce unnecessary setups
- Improve on-time delivery
- Lower production costs
- Increase machine utilization
By scheduling changeovers only when needed, manufacturers can streamline operations and enhance customer satisfaction.
Conclusion: Smarter Scheduling for Better Manufacturing Performance
Whether you’re in automotive, plastics, food processing, or any other industry, manufacturing scheduling software can help you make smarter decisions about changeovers. By minimizing downtime and optimizing setup timing, you’ll improve efficiency, reduce costs, and deliver products on time.