Creating a Setup Matrix

Use the Setup Matrix form to define the required setup time for changing a resource's setup from working on one type of item to another.

Just as you can define the Setup Basis on the operation for specifying when to apply setup time, you define the Setup Basis for the setup matrix to apply its setup time. A setup matrix can be based on the item changing or the setup group changing.

Item Basis Example

Suppose it takes 1 hour to set up the resource from polishing bike frames (item 0001) to polishing handlebars (item 1000). Likewise, it takes 1.5 hours to set up from polishing handlebars to polishing bike frames. The resource is not initially set up to paint either item. To represent this situation, you must define four records for your setup matrix:

• bike frames to handlebars
• handlebars to bike frames
• <DEFAULT> to bike frames
• <DEFAULT> to handlebars

NOTE: The <DEFAULT> identifier handles the cases where the current "From" index is not defined at the beginning of the scheduling run. This code is needed in this example because the resource is not initially set up to paint any item. You should define a "default" record for each To Item possibility. In this example, the resource only processes two items. You could use the <DEFAULT> identifier if the resource might process items other than 0001 and 1000, but you do not want to define a setup time for each combination. If the resource might process other items, you would define additional records: bike frames to <DEFAULT>, handlebars to <DEFAULT>, and <DEFAULT> to <DEFAULT>.

Follow these steps to set up this example setup matrix.

1. On the Setup Matrix form, select Actions > New.
2. In the Setup Matrix ID field, enter an identifier for this setup matrix. For example, enter Frame-Handlebar.
3. In the Setup Basis field, select Item.
4. In the From Item field, enter <DEFAULT> (with the < and > symbols).
5. In the To Item field, select the frame item number, 0001.
6. In the Setup Time field, enter a "generic" setup time to apply regardless of which To item causes the first setup. For example, enter 0.0001. For the <DEFAULT> record, you can enter a very small value, such as 0.0001, but it must be non-zero in order for the resource setup status to be changed.
7. Select Actions > Save to save this From-To record.
8. Select Actions > New.
9. In the Setup Matrix ID, select the Frame-Handlebar record you created in the previous steps.
10. In the From Item field, enter <DEFAULT> (with the < and > symbols).
11. In the To Item field, select the handlebars item number, 1000.
12. In the Setup Time field, enter a generic setup time, such as 0.0001.
13. Select Actions > Save.
14. Select Actions > New.
15. In the Setup Matrix ID, select the Frame-Handlebar record you created in the previous steps.
16. In the From Item field, select a valid From item number. For this example, select the bike frame item number, 0001.
17. In the To Item field, select the To item number. For this example, select the handlebars item number, 1000.
18. In the Setup Time field, enter the number of setup hours for this from-to sequence (for example, 1.00 hour).
19. Select Actions > Save.
20. Repeat steps 14-19 to set up a record to represent 1.5 hours of setup time with the From Item as item number 1000 and the To Item as item number 0001.

To configure an operation to use this setup matrix, you must select the appropriate fields on the Resources tab of the Current Operations form. Select Item in the Setup Basis field and Setup Matrix in the Setup Time Rule field. In the Setup Matrix field, select the Frame-Handlebar identifier for the matrix you created in the above steps.

Setup Group Basis Example

Suppose a resource is initially set up to paint RED bike frames and it takes 15 minutes to change the setup for painting BLUE frames. Likewise, it takes 10 minutes to change the setup from painting BLUE frames to painting RED frames.

Create the Setup Groups

1. On the Setup Groups form, define a BLUE setup group and a RED setup group.
2. On the Controls tab of the Items form, reference the appropriate Setup Group on each blue or red bike frame item record.

Create the Setup Matrix

To represent the situation in this example, you must enter seven records for your setup matrix:

• Red to Blue
• Blue to Red
• <DEFAULT> to Red
• Red to <DEFAULT>
• <DEFAULT> to Blue
• Blue to <DEFAULT>
• <DEFAULT> to <DEFAULT>

NOTE: Define a "default" setup time value for each situation where either the From or the To item is not a member of one of the defined setup groups.

1. On the Setup Matrix form, select Actions > New.
2. In the Setup Matrix ID field, enter an identifier for this setup matrix. For example, enter RedBlue.
3. In the Setup Basis field, select Setup Group.
4. In the From Setup Group field, select the RED setup group you created in the previous steps.
5. In the To Setup Group field, select the BLUE setup group.
6. In the Setup Time field, enter 0.25.
7. Select Actions > Save.
8. Repeat these steps to create the remaining six records (to represent the From-To situations listed above) for the RedBlue setup matrix.

To configure an operation to use this setup matrix, you must select the appropriate fields on the Resources tab of the Current Operations form. Select Group in the Setup Basis field and Setup Matrix in the Setup Time Rule field. In the Setup Matrix field, select the RedToBlue identifier for the matrix you created in the above steps.

Related Topics

Example: Setup Time

Operation Setup Time Overview