Setup time definition
/What is Setup Time?
Setup time is the interval needed to adjust the settings on a machine, so that it is ready to process a job. Shortening the amount of setup time is critical for engaging in short production runs, so that a business can more easily engage in just-in-time production. When this is done, a business can profitably run smaller batches of products, since there is a reduced setup cost associated with each incremental unit.
Many organizations have roving setup analysis teams that rotate through their production lines, employing best practices to analyze and compress machine setup times.
Example of Setup Time
A manufacturing company produces custom metal parts using a CNC (Computer Numerical Control) machine. The setup time is comprised of the following activities:
Remove previous job's tooling and materials: The operator removes the tools (e.g., drill bits, milling cutters) used for the previous production run.
Time: 10 minutes.
Install new tooling: New tools specific to the next job are installed and tightened securely.
Time: 15 minutes.
Load new program into the CNC machine: The operator uploads the program for the new part into the machine's computer.
Time: 5 minutes.
Calibrate tools and perform test runs: The operator calibrates the tools and runs a small test to ensure precision and accuracy. Adjustments are made if necessary.
Time: 20 minutes.
Prepare raw materials: New raw materials (e.g., metal sheets or blocks) are loaded onto the production line or machine.
Time: 10 minutes.
Final quality checks and adjustments: The first few items are produced and inspected to verify quality standards are met. If adjustments are needed, they are performed here.
Time: 10 minutes.
The total setup time is approximately 60 minutes to transition from one production run to another.