What does “setup time” mean?
Setup time is the period during which a machine or system is switched from manufacturing one product to another. For example, when manufacturing discrete parts, setup time is defined as the time from the last part of the old batch to the first part of the new batch.
Setup time is therefore not “waste” in the strict sense; however, since it involves, at least in part, machine downtime, longer setup times naturally reduce the productivity and efficiency of your production facilities.
Any process aimed at reducing setup time must always begin with an analysis of the setup operations: What steps are necessary? Which steps are currently being taken, and how much time do they require? In what order are the steps carried out, and can this order be changed? Which steps are truly necessary, and which ones can be optimized?
A thorough analysis must also address the following question: Is it possible to reduce the overall frequency of systems that are retooled—that is, to reduce the number of product changeovers? Less frequent retooling operations are, of course, less time-consuming and thus save money. At the same time, the costs saved as a result must be carefully weighed against the desire to keep inventory as low as possible—that is, to avoid overproduction of goods. And, of course, equipment utilization should remain as high as possible throughout this process.
In the context of setup time, a distinction is made between external setup (activities that are possible while the production line is running) and internal setup (for which the system must be shut down). Naturally, it is in your best interest to keep internal setup—which results in productivity losses—as short as possible.
With modern machinery, the thorough digitization and automation of setup processes is a crucial step. Tool presetters, for example, can determine the necessary tool data for a CNC machine tool in advance—that is, measure the tools and apply the correct settings directly. This dramatically reduces internal setup time, and electronic data transfer also prevents errors during transmission.
Since external measurement can take place on the presetting and measuring machine while the machine itself is still processing another order, additional time is saved: as soon as the machine is ready, the tools can be used immediately. There is no need to unnecessarily extend the machine’s downtime for laser measurement.
When it comes to all setup tasks—whether manual or electronic, external or internal—nothing beats well-trained setup operators. When employees are well-trained in setup workshops and on training machines, fewer errors occur, and difficulties are detected early on, before they lead to productivity losses.
A thorough analysis of setup times and the steps necessary during those times allows for the standardization of processes beyond the individual system. These, in turn, can be translated into clearer guidelines and training materials for your employees. This provides employees with additional guidance and safety—and also makes it easier to adapt to systems with which they are not yet fully familiar.
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