Rüstzeit
Also: Rüsten, Setup-Zeit, Umrüstzeit, Rüstaufwand, Rüstvorgänge, Setup time
AI-generated
Setup time refers to the period required to switch a machine, system, or workstation from a running order to a new order. It is non-productive time and directly affects capacity, batch size, and lead time.
Key facts
- Setup time is the non-productive period between two orders during which a system or workstation is prepared for the new order profile.
- Longer setup times force larger batch sizes, thereby increasing inventory levels and tied-up capital.
- The distinction between internal and external setup is the foundation of any systematic setup time reduction effort.
- Setup times occur not only in production but also at packaging, labeling, and picking systems in intralogistics.
- Reducing setup time increases system availability and enables more flexible, demand-driven manufacturing.
What is setup time?
Setup time is the period between the end of the last good unit of one order and the start of the first good unit of the next order. During this phase, neither production nor picking takes place: the system or workstation is reconfigured, cleaned, adjusted, or loaded with new materials. Setup time is therefore a form of non-productive time, yet it is unavoidable whenever different orders, products, or variants run on the same resources.
Setup time in intralogistics and production
In production, setup typically involves tool changes, adjustment of machine parameters, configuration of fixtures, and trial runs until the first defect-free unit is produced. In intralogistics, comparable setup times arise at packaging lines, labelers, palletizers, or manual picking workstations whenever the product format, packaging type, or order profile changes. Even in automated systems such as sorters or conveyor technology, a product changeover may require adjustments to the control system that must be counted as setup time.
Setup times can be divided into two categories:
- Internal setup: Activities that can only be carried out while the system is at a standstill — for example, physically changing a tool.
- External setup: Preparatory tasks that can take place in parallel with ongoing operations — for example, staging tools or materials at the workstation.
The goal of the SMED approach (Single Minute Exchange of Die) is to shift as many activities as possible from internal to external setup, thereby minimizing system downtime.
What matters when planning and selecting systems?
Setup times directly influence the optimal batch size: the longer the setup takes, the larger the batches planned, in order to spread setup costs across more units. However, this leads to higher inventory levels and longer lead times. Reducing setup times enables smaller, more frequent production runs — a key lever for flexibility and demand-driven manufacturing.
When evaluating systems and equipment, you should include setup time as a measurable criterion. Relevant factors include the average setup time per product changeover, the number of setups per shift, and whether setups can be shortened through standardization, quick-clamping systems, or software-based recipe management. Vendor claims regarding setup times should be verified during acceptance testing or a pilot operation, as actual setup time depends heavily on the product mix and the skill level of the staff.
Related terms
- Auftragsdurchlaufzeit
Order throughput time refers to the total time from the receipt of an order to its dispatch to the recipient. It encompasses all waiting, processing, and internal transport steps, and serves as a key indicator of the performance of a warehouse or fulfillment process.
- Auftragsfertigung
Make-to-order refers to a production model in which the manufacture of a product does not begin until a specific customer order has been received. Unlike make-to-stock production, goods are produced individually for each customer and demand-driven.
- BDE-System
A BDE system (operational data collection system) captures machine and manual process data in real time directly at the source – such as at machines, conveyor systems, or workstations.
- Bedarfsplanung
Demand planning refers to the systematic process by which a company determines what quantities of materials, goods, or resources are needed and when. It forms the foundation for inventory management, procurement, and warehouse planning.
- Bestandsmanagement
Inventory management refers to the systematic planning, control, and monitoring of stock levels across the entire supply chain. The goal is to ensure delivery capability while keeping capital commitment and warehousing costs within economically viable limits.
- Bottleneck Analyse
Bottleneck analysis identifies the process step with the lowest capacity in a logistics system, making the limiting factor for overall throughput visible.
- Disposition
Disposition refers to the operational planning and control of resources, quantities, and orders in logistics – for example in transport or materials disposition. It encompasses capacity assignment, scheduling, prioritization, and response to disruptions.