What's considered setup time?
Setup time is the duration of setup from start to end. Activating a job automatically transitions the machine to a setup state as it is common to calibrate, clean and make other adjustments to the machine prior production.
During setup it is common to run machines for producing test units. It depends on your site's policy if all the setup duration is considered downtime, or if the time during setup in which machines worked is counted as production time. Another policy decision is how to address units produced during setup: should they all be considered rejects, or should only those that are faulty be counted as rejects?
How to count setup downtime and how to label setup rejects' are important decisions since they impact KPIs, such as your OEE.
In Matics you'll set the setup duration standard and the system will compare the actual setup's duration to the standard for analysis, planning and triggering remedial actions.
Setup time can be ended manually, or ended automatically after a number of cycles. It can also use a combination in which the auto-logged setup end time and setup events are corrected retroactively. Timely reporting / retroactive setup time adjustments ensure that the production timeline accurately reflects the machine's activity.
Setup is considered an event (similar to stop events), which you can divide into sub-setup events to fine-tune tracking and analysis. In general, the goal is efficient setups that are as short as possible.
The Setup standard
Setup standards are the expected base duration for setup -- the 100% duration in minutes.
Spoiler alert: since different contexts may require adjusted setup durations, this 100% duration will be extended or shortened when applying setup types.
Setup standards are usually configured first at the system-wide level of machine types and machines by Matics personnel.
These base standards can then be adjusted as needed at the granular, context-specific configuration level of molds, products and jobs, by various system users.
Setting the setup standard for machine types (Matics personnel)
The machine type level not only offers the option of setting the high-level setup duration standard for all machines of that type, but also the option of nuancing this through setup types.
Go to Setup > Site Configuration > index 5 (Step 5 - Define Machine Types).
Select the applicable machine type by clicking its index number.
In the machine type's General tab > Setup section enter the number of minutes for Valid Setup Duration (Min).
Save changes.
Fine-tuning this setup standard with setup types (Matics personnel)
You can define different types of setup and set for each type its duration standard. Having a benchmark to compare the actual time spent on setup with the standard for that specific type of setup, provides important information for planning production and for measuring performance.
Creating setup types
Still in the Machine Type's form, click the Setup Types tab.
Click Add.
In the new row that's added:
Name: enter a name for this setup type.
Set a color to color-code the machine which is in this setup type state.
Set the percent from the machine type's set standard setup duration (the base standard, which is the 100%) that's expected for this setup type.
If the duration should be longer than the base standard you'd enter a value above 100.Set whether this is the default type of setup for this machine type.
(optional) enter the number of cycles after which setup will end automatically. This relates to the Setup End Definition By policy. See ending setup.
NOTE: To end setup immediately upon job activation enter the value of 1. This means the job will have no setup time.
Entering a value of 0, or leaving this field blank, will require ending setup manually.
Click Save changes.
If you want to translate the label of this setup type, click the Language index to do so and save changes.
Applying setup types
Setup types can be applied at two levels:
Machine Type level - Set for the machine type its default setup type, and that will determine for the job its default valid duration.
Job level - Override the machine type level default by choosing a different setup type at the job level. This will automatically update the Valid Setup Duration (Min) value.
If there's no setup type that matches the valid setup duration for this job, you can just change the Valid Setup Duration (Min) value. This value will be the standard used for setup duration analytics.
Even if not using the valid setup duration value set for the setup type, there are other setup-type configurations that may be used in the job, such as the Setup End Definition By policy & color coding.
Setting the setup standard for specific machines (Matics personnel)
At the machine level you can set for each machine its default setup duration.
Go to Setup > Site Configuration > index 5 (Step 5 - Define Machine Types).
Select the applicable machine type by clicking its index number.
Click the Machines tab.
Select the applicable machine by clicking its index number.
In the machine's General tab > Setup section enter the number of minutes for Valid Setup Duration (Min) and save changes.
NOTE
If there's a default setup type set for the machine type, when selecting the machine the job will run on, the setup type's logic will be applied to that machine's standard.
For example, if the default Setup Type is 50% of the Valid Setup Duration, and the machine level's setup duration standard is 60 minutes then the job's setup duration standard will be 30 minutes, unless changed manually by users.
Molds' setup duration standard
Setting the mold's setup standard usually depends on the industry and how the client manages the production process. For example, if for injection molds each mold requires a different setup duration they can decide to manage the setup duration either through the mold, or through the product. If you are managing the setup duration standard through the mold, do so from the target mold's form. In this procedure we accessed it from the main menu, but it can be accessed from various contexts in the system.
Go to Resources > Molds.
(optional) Filter the list of molds.
Click the index of the target mold.
In the mold's General tab > Setup section enter the number of minutes for Mounting Duration and save changes.
TIP
If your setup procedure requires first dismounting a mold and then mounting another mold, enter the aggregated time in this field, since this would be the standard to compare to.
Products' setup duration standard
Open the target product form. In this procedure we accessed the product form from the main menu, but it can be accessed from various contexts in the system.
Go to Production > Products.
(optional) Filter the list of products.
Click the index of the target product.
In the product's General tab > enter the number of minutes for Valid Setup Duration (Min).
Save changes.
Jobs' setup duration standard
Setting the setup duration standard at the job level can be especially useful for making adjustments to the standard set at higher levels, which cannot take in account the specific context the job will be running. For example, if the same product is produced in two successive jobs the machine setup time would remain the same, but if not and the following job is for producing a different product that requires thorough cleansing of the machine from residue of the previous product, that job's setup duration would be longer.
To set the job's setup duration standard open the target job form. In this procedure we accessed the job form from the main menu, but it can be accessed from various contexts in the system, for example the Gantt.
Go to Jobs > Jobs Report.
(optional) Filter the list of jobs.
Click the index of the target job.
In the job's General tab > Setup section enter the number of minutes for Valid Setup Duration (Min) and save changes.
TIP
You can also set the setup duration standard by choosing the relevant setup type for this job.
NOTE
If there is no setup type or setup valid duration set at the job level, the job's setup type is based on what was set for the machine type.
Setup policies
NOTE
When the same policy can be set at different levels in the system, the most granular level--typically Job-level settings--will override settings of that policy at other levels.
Should production during setup be counted as downtime?
This is a critical policy as mentioned above in What's considered setup time? since it will impact KPIs and will be reflected in analytics and statistics.
This policy is set by Matics personnel at the machine level through the Monitor Setup Working Time check box. If active, setup time is logged per the machine's actual states during setup: how much of setup time was the machine in production and how much of setup time the machine was in downtime (not producing). If monitoring is not active, all the setup duration is considered to be downtime.
Ending setup automatically
There can be various reasons for setting this policy, such as a setup procedure in which the machine is run for a certain number of cycles and that completes the setup phase, or sites in which there's no setup at all.
This policy can be set at the system level by Matics personnel for machine types through the Setup End Definition By parameter choosing one of the two methods:
Setup Types - The value set for Cycles to Automatic Setup End in the applied setup type will end setup automatically if it wasn't ended manually by then.
OR
Job Definitions - The value set for Cycles to Automatic Setup End in the applied Job definition will end setup automatically if it wasn't ended manually by then.
Also at the system level, there's the machine setting Cycles to Automatic Setup End. The value you set here will override the machine type setting for determining the automatic end of setup, which could be based on setup types or job definitions.
To end setup immediately upon job activation enter the value of 1. This means the job will have no setup time. Entering a value of 0, or leaving this field blank, will require ending setup manually.
Polices that base the end of setup on job definitions use the value for Cycles to Automatic Setup End set for the job definition. Applying the relevant job definition is done through the job form's:
General tab > Resource Planning section > Job Type list.
Enforce running QC tests before ending setup
Block the option of ending setup if a QC test wasn't ordered and passed. Enable this by choosing the test.
The Setup must include this QC test setting is available at the machine type level, machine level, product level and job level. The most granular level setting is the one that applies. Clip
Should setup be resumed when suspended jobs are reactivated?
There's a default setup policy determined by the system variable:
SetupEndStateForLastJobActivation
(Setup > Site Configuration > Step 7: Define System Variables > More Settings tab), which determines how and whether to append setup time when reactivating jobs through the Operator app on the tablet for machines in production state.
If this variable is set to Automatic, it depends on whether the job was in the midst of setup when it was suspended.
If it was, reactivating the job will resume the job in setup state and continue the count for setup time from that point until setup end.
If it wasn't, reactivating the job will not start setup again.
If this variable is set to Start, reactivated jobs will start in Setup state.
By default, should units produced during setup be considered good units or rejects?
This policy is set by Matics personnel at the machine level through the Setup Rejects check box. If active, the count of units produced during setup is added to the general count of rejects at the end of setup (during setup these units are considered good units).
If not active, all units produced during setup are counted at the end as good units.
NOTE
The operator app prompt at end of setup depends on whether this setting is active or not. If active, operators are requested to enter manually the number of good units. If inactive, operators are prompted to enter the number of rejects.
How to integrate the auto-count of rejects during setup?
This policy is set by Matics personnel at the machine level through the Allow Auto Rejects On Setup check box.
It's only applicable to machines with a controller that counts rejects. If reading the PLC's auto-reject data is enabled (see below), the automatic count is used by Matics as another layer of information in insights and jobs.
NOTE
If this setting is active on the machine, it doesn't make sense to activate the Setup Rejects setting too, since this could create a multiple count of rejects.
Enabling auto-reject data is done for each relevant machine parameter as follows:
Go to Setup > Site Configuration > index 5 (Step 5 - Define Machine Types).
Select the applicable machine type by clicking its index number.
Click the Machines tab.
Select the applicable machine by clicking its index number.
Click the machine's Parameters tab .
(Optional) apply filtering to quickly find the relevant parameter.
Click the target parameter's index number. This will open the parameter's Controller Field form. In it configure the following:
Auto Reject Direct From PLC - Select this check box to collect data from the auto-reject controller in this machine.
Reject Reason - Choose the reject reason these rejects will be tagged with.
Reject Option - Select how reject reasons are logged.
Save changes.
Setup event tagging policies
Tagging setup events is dependent on how the following three polices were configured by Matics personnel at the machine type level:
Allow Perform Actions on Setup Events
If active, and the machine is in setup mode, users can report events generated during setup time using any of the setup event reasons, and also split the setup event as needed.
If not active, events generated during setup are automatically classified as setup events.
Allow Reclassifying Setup Events (Clip)
NOTE: During setup, events are automatically tagged as setup events. Reclassifying these events can only be done after setup is completed.If active, users can change the classification of events reported as setup events. This is useful if they forgot to end setup, and when setup event data needs to be reclassified to accurately reflect the job's events' reasons and duration.
If not active, once an event is reported as a setup event, the event's classification cannot be changed.
Allow Reporting Setup Events on Active Job
This is useful for accurate tagging of events and also for counting aggregated setup duration downtime.
NOTE: If Allow Reclassifying Setup Events (see above) is NOT active, once an event is reported as a setup event, this classification cannot be changed.If active, Operator app users will have the Setup event group and its reasons available for reporting setup processes during production time.
For example, loading raw materials or replacing packaging materials can be associated to the setup events category while the job is running if they were not carried out during the job's initial setup time.
Getting alerts during setup for deviations in specific standards
This policy is set by Matics personnel at the machine level through the Alarms During Setup check box. Select this check box if the client wants to get alerts during setup for machine properties that have deviated from their standard.
(For this to work, alerts for those properties should be enabled in the machine's Parameters > Alarms tab.)
Incorporating setup events into end of setup / end of shift
These policies are set by Matics personnel at the machine level.
The Setup Event On Setup End setting determines what type of event is generated and logged at the end of setup:
Setup - Setup event means the machine remains in production mode, but in downtime setup.
Calendar - Setup will end by generating a calendar event. This enables setting for the generated calendar event the logged Production Status as well as what production status should be activated when the event ends. This setting would work well when the machine is entering non-production state for the weekend.
NOTE
Machines' production state differs per the type of event at the end of setup, while the job's state will remain setup, regardless of the event type.
The Setup Event On Shift End setting determines what type of event is generated and logged at the end of the shift:
Setup - Setup event means the machine remains in production mode, but in downtime setup. This could work well when there's a following shift.
Calendar - End of shift will generate a calendar event. This enables setting for the generated calendar event the logged Production Status as well as what production status should be activated when the event ends.
Setup policies for molds
In the mold form's Setup section you'll find various setup settings. All these policies are informative only--they neither determine nor enforce operational conditions.
Mounting Instructions - If during setup users are expected to mount the mold, you can enter here free-text instructions on how to do so.
Dismounting Instructions - If during setup users are expected to dismount this mold, you can enter here free-text instructions on how to do so.
Dismounting Duration - Numeric value indicating how long dismounting a mounted mold is expected to take.
Series Approval Duration (Min.) - (deprecated)
Setup event tags for classification
The Setup event group
As mentioned above in What's considered setup time? Setup is considered an event (similar to stop events) which you can divide into sub-setup event types for tracking and analysis.
In the Settings > Stop Events Customization > Events Customization page the Setup event group is a system event group that's listed by default, with a single reason member in the group called Setup. This group and reason are the minimum setup events, and you can add event reasons that reflect your site's requirements.
Adding Setup event reasons
To maximize the reporting, tracking and analysis of setup events you are expected to add setup event reasons that reflect your production site.
To do so:
Go to Settings > Stop Events Customization > Events Customization.
Expand the Setup event group.
Click the edit control.
Click + to add an event reason.
Configure the following parameters;
Type - setup time is considered downtime.
Color and Machine status are especially useful for color coding machines.
Machines - to which departments and machines this setup reason applies.
ERP ID - If there's an ERP ID for this setup reason, enter it here.
Active - Select this check box, otherwise this reason won't be available for use.
Op app - Select this check box to enable tagging setup reasons through the Operator app.
NOTE: Tagging setup event reasons also requires enabling tagging policies as described above.Target (%) - Enter the target downtime percentage for setup. This will be used in the PE waterfall (insight 205) to indicate how the actual setup downtime relates to the target setup downtime.
If for example you've set the Target (%) to30, in the PE waterfall insight it could look like this:
14.29%is the actual setup duration (7h 29m) converted to percentage of the total production time.
30% - 14.29% = -15.71%indicates that the actual downtime is less than the target setup downtime, which is better than expected and therefore color-coded in green.
Click Save.
Ending setup manually
Ending setup through the Operator app is done either from a widget or the job action.
Ending setup through the Web app is done in various contexts via the machine's Actions menu.
Related articles
Activating a Job via the Operator App (there's a flow of what to do about setup if you're reactivating a job).