SIPLACE Floating Setup

“Floating setup” is a type of setup changeover that is executed without slowing down or stopping the line. Under certain conditions floating setup delivers non-stop production with maximum flexibility. High-mix lines can achieve throughput rates that were previously only possible in large-volume environments. With this setup concept, a line can run with almost no interruptions to deliver a virtual maximum of line productivity.

Users can choose whether they want a setup that is optimized in terms of head travel (for maximum placement performance) or a setup where they are able to position feeders conveniently in any open slot (called random setup) for very fast setup speed.

Floating feeder-oriented setup
In this kind of setup changeover, feeder modules which are no longer needed are replaced with feeder modules for the next product while the line keeps running. To achieve the necessary setup performance and be able to plan an efficient production schedule, the use of SIPLACE LES (Line Execution System) is highly recommended. SIPLACE LES controls all setup related processes on the line, from job sequencing to material preparation to the actual setup changeover at the line (setup and tear down).

Floating block-oriented setup
Creating setup blocks is an alternative method of simplifying setup changeovers. With setup blocks, the feeder table is split into two contiguous blocks of feeders, one for product group A, which is currently running, and one for the upcoming product group B. While A is running, B can be set up. To optimize the setups for A and B, the SIPLACE Split Table Mode in SIPLACE Pro can be employed and combined with SIPLACE SiCluster.

Floating setup with fixed side of the line
Using dual-track conveyors with suitable setup changeover concepts is an attractive way to increase efficiency when high volume and high-mix requirements have to be combined.

“Floating setup” characteristics

Production environment

Planning (Long planning horizon:+++;
short planning horizon: —)

Average lot size

Setup changeovers per shift

SIPLACE Features

With fixed setup on the line

—
 
 
 

1/>200

1-3
 

SIPLACE Pro Optimizer

SIPLACE SiCluster Professional

SIPLACE Setup Center
 

Random Setup (an Linie)

Block-wise
 

+
 
 
 

5-50

>5
 

SIPLACE Pro Optimizer

SIPLACE Split Table Mode
 

SIPLACE SiCluster Professional

SIPLACE Setup Center

Random Setup (an Linie)

SIPLACE LES

Feeder-by-feeder
 

—
 
 
 

1-5

>5
 

SIPLACE Pro Optimizer

SIPLACE Split Table Mode
 

SIPLACE SiCluster Professional

SIPLACE Setup Center

Random Setup (an Linie)

SIPLACE LES