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Changeover Matrices and Fixed Scrap Logic

Plan and control changeovers and scrap in cable production. Use matrices and fixed scrap logic in factory.online to optimize schedules, reduce waste, and improve accuracy.

Updated over 4 months ago

Plan Around the Inevitable

Changeovers and scrap are part of cable production – but that doesn’t mean they can’t be controlled. factory.online helps you plan for them, measure them, and reduce their cost.

Changeover Matrices

Cable machines often need significant time to switch between:

  • Wire sizes

  • Material grades

  • Number of strands

  • Screen/armoring types

How It Works

  • You define matrix rules:
    e.g. Change from copper to steel = 25 min
    e.g. Change from 24 to 56 wires = 40 min

  • Scheduler adds this time automatically between job orders

  • Supports different rules for manual vs. automated changeovers

Modes

  • Additive Mode: Sum all change times

  • Max Mode: Use only the longest one (for assisted teams)

Fixed Scrap Logic

Some processes always result in predictable waste:

  • Start-up scrap

  • Take-up/payout lengths

  • Equipment configuration meters

Example:

  • Extrusion: 3m take-up + 5m payout + 50m tuning = 58m scrap per batch

System accounts for this:

  • When planning material demand

  • When evaluating actual yield vs. theoretical

Benefits

  • More accurate material planning

  • Shorter changeovers through optimization

  • True performance visibility by job, line, and shift

Stop guessing changeover and scrap. Start controlling them.

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