When configuring Setup Elimination, two settings determine how long a machine’s current setup can be reused:

• Default Idle Allowance
• Absolute Allowance

Although both settings influence when a new setup operation is required, they solve different scheduling problems.

Understanding the difference between them is essential for producing realistic schedules.

Default Idle Allowance

The Default Idle Allowance specifies how long a machine may remain idle before its current setup is considered lost.

In many manufacturing environments, a machine can sit unused for a short period without requiring another setup. Operators may be waiting for material, taking a scheduled break, or preparing the next job while the machine remains configured.

If the idle period is shorter than the configured allowance, MxAPS assumes the setup is still valid and can be reused.

Example

Suppose the following configuration:

• Default Idle Allowance: 30 minutes

Production proceeds as follows:

Time	Activity
10:00 AM	Job A finishes
10:20 AM	Job B begins
Setup Elimination Code	Same for both jobs

Because the machine was idle for only 20 minutes, MxAPS continues using the existing setup.

If Job B instead started at 10:45 AM, the idle time would exceed the configured allowance. MxAPS would schedule a new setup before Job B begins.

The Default Idle Allowance measures how long the machine sits unused.

Absolute Allowance

The Absolute Allowance limits how long a setup may be continuously reused, even when production never stops.

Some manufacturing processes require periodic cleaning, inspection, calibration, or maintenance after a machine has operated for a certain amount of time.

The Absolute Allowance ensures these requirements are respected.

Example

Suppose the following configuration:

• Absolute Allowance: 8 hours

Several production orders with the same Setup Elimination Code are scheduled consecutively:

Time	Activity
8:00 AM	Job A begins
10:00 AM	Job B begins
12:00 PM	Job C begins
2:00 PM	Job D begins
4:00 PM	Job E begins

Although every job uses the same setup, once the continuous production time exceeds eight hours, MxAPS inserts a new setup before continuing production.

The Absolute Allowance measures how long the setup has remained continuously in use.

Comparing the Two Settings

Setting	Measures	Triggers a New Setup When…
Default Idle Allowance	Machine idle time	The machine has been idle longer than the configured allowance.
Absolute Allowance	Continuous setup duration	The current setup has been used continuously longer than the configured limit.

A useful way to think about them is:

• Idle Allowance asks: Has the machine been sitting long enough that we should assume the setup is no longer valid?
• Absolute Allowance asks: Has this setup been used for so long that we should refresh it anyway?

How the Settings Work Together

Both settings are evaluated when MxAPS determines whether a setup can be eliminated.

A setup can only be reused when:

• the Setup Elimination Code matches,
• the machine has not been idle longer than the Default Idle Allowance, and
• the continuous runtime has not exceeded the Absolute Allowance.

If any of these conditions are not met, MxAPS schedules a new setup operation.

Example Manufacturing Scenarios

Food Manufacturing

A packaging line can remain idle for 15 minutes during shift change without requiring another sanitation cycle.

• Default Idle Allowance: 15 minutes

However, food safety regulations require cleaning every eight hours of production.

• Absolute Allowance: 8 hours

Short pauses do not trigger cleaning, but extended production eventually does.

Paint Line

A paint booth can remain idle while operators stage the next job without cleaning the equipment.

• Default Idle Allowance: 20 minutes

After several hours of continuous painting, filters and spray equipment must be cleaned.

• Absolute Allowance: 6 hours

Metal Fabrication

A laser cutter can remain idle while material is loaded.

• Default Idle Allowance: 30 minutes

After extended production, lenses require inspection and cleaning.

• Absolute Allowance: 10 hours

Best Practices

When configuring these settings:

• Set the Default Idle Allowance to reflect how long a machine can realistically remain idle without losing its setup.
• Set the Absolute Allowance to match mandatory cleaning, inspection, maintenance, or calibration intervals.
• Validate the resulting schedule using representative production orders to ensure setup operations occur at the expected times.

Properly balancing these two settings allows MxAPS to minimize unnecessary changeovers while still producing schedules that reflect real-world manufacturing requirements.