A set-up matrix is a powerful tool for detailed optimization of production for recurring batches of similar or identical products. The challenge is to determine the transition periods from one product to the next with sufficient precision and to provide the findings for a planning system.
A set-up matrix describes how long it takes to convert from one product to any other product on a plant, although simplification is possible even with similar costs by analyzing product group by product group.
Modern PPS systems allow a setup matrix to be stored in the master data, which can then be used in the planning process. A setup matrix is composed of set-up processes measured in real operation in the past and can be visualized as follows, for example.
oee.ai automatically determines the set-up matrices, including the previous elimination of outliers due to possible incorrect input from employees. The matrices are made available at an API endpoint for further use in planning systems.
An automated set-up matrix based on real set-up times and therefore constantly updated creates advantages for companies in two places.
Setup matrix to optimize the set-up sequence
With a setup matrix, sequence planning can be optimized by planning products one after the other on a machine with short conversion times. As a rule, this requires a dynamic adjustment of batch sizes at the same time so that customer requirements are actually met. Ideal sequence optimization, in particular for a broad product portfolio and across multiple systems, is therefore a complex optimization problem that is regularly inconceivable without the use of a PPS system. oee.ai can support this process by digitally providing an up-to-date setup matrix.
One form of representation of the optimal set-up sequence for a given — and ideally stable — production program is the gear wheel. This can be combined with the code EPI, which indicates how long it takes to pass through the preparation wheel.
Setup matrix for precise production planning
Production planning involves predicting future plant occupancy. How product and plant-specific OEE improves production planning has been described in another article. In addition, it should be explained that a precisely specified set-up time also provides an advantage in production. In this way, employees can be notified of the remaining set-up time on an Andon board in order to compare this with the remaining effort based on the employees' experience and thus be able to reach the target time.
Production planning with precise set-up times is of additional importance in companies where set-up is carried out frequently or the order lead time until the next planning slot is very long. In these cases, imprecise set-up values generate deviations between planning and reality, which are manifested at least in a constant need for planning adjustment and can continue until delivery to customers is delayed.
If you are interested in discussing the topic of data-based production optimization, please feel free to contact us.