Setup Elimination Codes: Limiting Setup Time by Item or Item Group

Use setup elimination codes to tell MxAPS when setup time may be removed between consecutive operations. The code is the grouping key: setup can be eliminated only when the previous and next scheduled operations use the same setup elimination code and the rest of the setup elimination record parameters match.

This means setup elimination codes must be assigned at the level where setup can truly be skipped. If setup should only be removed between batches of the same item, use a unique setup elimination code for each item. If setup can also be skipped between different items that share the same changeover characteristics, those items may intentionally share one setup elimination code.

Also refer to https://kb.dmsiworks.com/knowledge-base/configuring-native-setup-eliminations/

Recommended configuration for same-item batching

When the requirement is:

• remove setup time between consecutive batches of the same item; and
• keep setup time when a different item follows immediately afterward;

configure one setup elimination code per item number.

Do not assign a common code such as NOCOMBINE to all items unless setup should be eliminated between all of those items. If ITEM-BLUE-01 and ITEM-BLUE-02 both use NOCOMBINE, MxAPS treats them as part of the same elimination group, so the setup between those different items may be removed when they are scheduled consecutively.

When to share a setup elimination code

Share a setup elimination code only when the setup may be skipped between different items in the same group. Examples might include items that use the same fixture, tooling, color, cleaning state, or other physical characteristic where no changeover is needed.

Example grouping:

In this example, setup can be eliminated between ITEM-BLUE-01 and ITEM-BLUE-02, but setup is retained between a blue item and a red item because the setup elimination codes differ.

Configuration steps

1. Open Setup Elimination Codes.
2. Create the setup elimination codes at the correct grouping level:
   • one code per item if only identical item batches should skip setup; or
   • one code per valid setup family if different items can legitimately skip setup between one another.
3. Open Setup Eliminations.
4. Create a setup elimination record for each item or item group member that may have setup removed.
5. Assign the appropriate Setup Elimination Code to each record.
6. Set the applicable capacity, segment, and allowance fields:
   • Capacity Type and Capacity No. limit elimination to specific work centers or machine centers. Leave Capacity No. blank only when elimination is valid on any equipment.
   • From Segment and To Segment define which setup segments can be removed.
   • Idle Allowance defines the maximum idle gap that can occur and still allow elimination.
   • Absolute Allowance defines the maximum elapsed time of any kind between operations and still allow elimination.
7. Run the schedule and validate both same-item and different-item transitions.

Validation checklist

After setup elimination is configured, review the schedule for these cases:

• Same item followed by the same item with the same setup elimination code: setup should be eliminated when all configured parameters and allowances permit it.
• Different item followed by a different item with different setup elimination codes: setup should remain, even if there is no idle gap between operations.
• Different item followed by a different item with the same setup elimination code: setup should be eliminated only if those items were intentionally grouped because no changeover is required.
• Same setup elimination code but different equipment, segment, alternate ID, variant, or allowance conditions: setup is eliminated only when the configured record parameters allow it.

Troubleshooting

Setup is removed between different items

Check whether both items share the same setup elimination code. If setup should only be removed between identical item batches, change the configuration so each item has its own code, such as using ITEM-BLUE-01 for item ITEM-BLUE-01 and ITEM-BLUE-02 for item ITEM-BLUE-02.

Setup is retained between same-item batches

Confirm that the consecutive operations use the same setup elimination code and that the applicable setup elimination records match the scheduled operation details. Also verify that the idle and absolute allowances are large enough for the time between the two operations.

Setup behavior changes when there is no time gap

Do not use the presence or absence of a time gap as the primary grouping control. The setup elimination code identifies whether two operations belong to the same elimination group. If different items share the same code, MxAPS can treat an immediate transition as eligible for elimination. Use distinct codes when the transition should keep setup time.