Maintain Changeovers
Purpose
To maintain the rules that Phenix uses to calculate the duration and cost of changeovers or setups.
Prerequisites
Material attributes created and assigned to Material Types. Materials created, assigned a Material Type, and Attributes filled out.
Steps
Click on the menu path Setup>Changeovers.
This is the Changeovers page, where you can create and edit an organization’s changeovers.
Standard Changeovers
It is recommended to create a Standard Changeover before creating a Changeover Rule, especially if there are several changeovers with the same length and additional cost.
To create a new Standard Changeover, click Create.
To edit an existing Standard Changeover, click Edit in the right “Actions” column of the Standard Changeover’s entry.
Creating or editing a Standard Changeover opens a window with the following inputs:
Name: The name of the Standard Changeover.
Time in Minutes: The length of time, in minutes, the changeover is expected to take.
Additional Cost: Optional. The extra cost associated with the changeover, not from loss of production.
Consumed Resource: Optional. The Resource used when the changeover occurs.
To delete an existing Standard Changeover, click in the right “Actions” column of the Standard Changeover’s entry.
Changeover Rules
Changeover Rules define the actual changeovers that are seen in the Wheel Designer and in scheduling.
To create a new Changeover Rule, click Create.
To edit an existing Changeover Rule, click Edit in the right “Actions” column of the Changeover Rule’s entry.
Creating or editing a Changeover Rule opens a window with the same inputs, which vary by Rule Type. See Changeover Rule Inputs below for more information.
To delete an existing Changeover Rule, click in the right “Actions” column of the Changeover Rule’s entry.
Changeover Rule Inputs
General Inputs
Name: Description of the changeover. Typically, what is being changed.
Rule Type: The general category of the rule. Choosen from following options:
Combination: A changeover rule which is a combination of several other changeover rules. This allows multiple changeovers to apply consecutively, instead of the standard Phenix process of using the longest changeover and assuming other changeovers will occur during the same timeframe.
Contaminant Clean: The changeover works on Attributes of type “Contaminant”. If the list of contaminants of product-from is a subset of the list of contaminants of product-to, no specific cleaning is required. However, if some contaminants of product-from are not in the list for product-to, the rule will be triggered. One of the more commonly used rule types.
Default: The rule occurs between products if no other rules do.
Line Mode Change: A rule triggered by a Line Attribute changing.
Material Attribute Changed: Triggered when the value of the previous Material’s attribute is different from the value of the next Material’s attribute.
Order Attribute Changed: Triggered when the value of the previous Order’s attribute is different from the value of the next Order’s attribute.
Periodic: Changeover is not triggered by Orders and Materials, but always occurs after a specified period of time.
Simple: For special case changeovers that do not fall under the other categories.
Time in Minutes: The length of time, in minutes, the changeover is expected to take.
Additional Cost: Optional. The extra cost associated with the changeover, not from loss of production.
Combination Rule Type Inputs
Rules: Search for an existing changeover rule to add to the combination rule. Use the “+ Add” button to additional fields with which to add further changeover rules to the combination rules.
Contaminant Clean Rule Type Inputs
Material attribute containing comma separated contaminants: Select Attribute from list of user-created Material Attribute (of type “contaminant”) that contains the contaminant list the changeover applies to.
In order to remove this contaminant: Optional. If a specific contaminant’s removal causes a special cleaning, use this to specify the contaminant value.
Apply when changing FROM materials matching: Optional. Sets rule to apply when the Material being changed from matches the filter entered here (see Phenix Filtering Syntax for more on how these filters are structured).
Apply when changing TO materials matching: Optional. Sets rule to apply when the Material being changed to matches the filter entered here (see Phenix Filtering Syntax for more on how these filters are structured).
Default Rule Type Inputs
No unique input options.
Line Mode Change Rule Type
Select attribute: Select from the list of user-created Line Attributes of type “Operating-mode” that contains the values that trigger the changeover. (For more information on Line Attributes, see Maintain Line Types and Attributes).
From mode: Optional. Sets rule to apply when the Line Mode being changed from is the entered value. Leave blank to apply to any.
To mode: Optional. Sets rule to apply when the Line Mode being changed to is the entered value. Leave blank to apply to any.
Material Attribute Changed Rule Type
Material attribute to apply this to: Select Attribute from list of user-created Material Attributes (of any type) that contains the values that trigger the changeover.
Apply when changing FROM materials matching: Optional. Sets rule to apply when the Material being changed from matches the filter entered here (see Phenix Filtering Syntax for more on how these filters are structured).
Apply when changing TO materials matching: Optional. Sets rule to apply when the Material being changed to matches the filter entered here (see Phenix Filtering Syntax for more on how these filters are structured).
Order Attribute Changed Rule Type
Select order attribute: Select Attribute from list of user-created Order Attributes (of any type) that contains the values that trigger the changeover.
Apply when changing FROM materials matching: Optional. Sets rule to apply when the Material being changed from matches the filter entered here (see Phenix Filtering Syntax for more on how these filters are structured).
Apply when changing TO materials matching: Optional. Sets rule to apply when the Material being changed to matches the filter entered here (see Phenix Filtering Syntax for more on how these filters are structured).
Periodic Rule Type
Default time between (hours): The number of hours after one instance of the changeover after which another instance should occur.
Maximum time between (hours): The number of hours after one instance of the changeover after which the next instance must occur.
Simple Rule Type
Apply when changing FROM materials matching: Optional. Sets rule to apply when the Material being changed from matches the filter entered here (see Phenix Filtering Syntax for more on how these filters are structured).
Apply when changing TO materials matching: Optional. Sets rule to apply when the Material being changed to matches the filter entered here (see Phenix Filtering Syntax for more on how these filters are structured).
Advanced Options (All Optional)
Many of the advanced options in changeover rule creation are shared across multiple types. For example, all changeover rule types have access to the Priority Override advanced option. To avoid redundancy, advanced options will only be fully described the first time they are encountered.
Customize Time for Wheel Design: Use when the changeover should be used differently in Wheel Design than it should be in scheduling.
Consumed Resource: The Resource used when the changeover occurs.
Priority Override: Determines what priority the changeover is. If multiple changeovers could apply between two items, Phenix will assume the lower priority changeover will occur within the time set aside by the higher priority changeover. Leave blank to apply a default priority based on changeover length
Add New “Line” Condition: Creates a new configuration box that allows you to control what influence the production line has over this changeover rule. The options within are:
Apply/Don’t Apply: Allows the user to set the rule to apply if conditions match the second setting, or not apply if conditions match the second setting.
Name/Type/Attribute: Allows the user to set what characteristic of the production line is being checked. For each of these options, a text field will appear allowing the user to find a specific line, line type, or attribute. If “Attribute” is selected, the user can set a specific value for the attribute.
Remove Condition: Deletes the condition from the rule.
Add New “Order” Condition: Works similarly to Add New “Line” Condition, save that order attributes are checked instead.
Apply/Don’t Apply: Allows the user to set the rule to apply if conditions match the second setting, or not apply if conditions match the second setting.
Attribute: Allows the user to set what characteristic of the order is being checked. Once chosen, two text fields will appear, allowing the user to find a specific order attribute to check as well as a value for that attribute.
Advanced Options for the Combination Rule Type
Add New “Material From” Condition: Similar to “Add New ‘Line’ Condition”, save that it concerns materials rather than production lines. More specifically, this setting checks the material before the changeover would occur for the specified characteristics.
Apply/Don’t Apply: Allows the user to set the rule to apply if conditions match the second setting, or not apply if conditions match the second setting.
Name/Type/Attribute: Allows the user to set what characteristic of the material is being checked. For each of these options, a text field will appear allowing the user to find a specific material, material type, or material attribute. If “Attribute” is selected, the user can set a specific value for the attribute.
Add New “Material To” Condition: Similar to “Add New ‘Line’ Condition”, save that it concerns materials rather than production lines. More specifically, this setting checks the material after the changeover would occur for the specified characteristics.
Apply/Don’t Apply: Allows the user to set the rule to apply if conditions match the second setting, or not apply if conditions match the second setting.
Name/Type/Attribute: Allows the user to set what characteristic of the material is being checked. For each of these options, a text field will appear allowing the user to find a specific material, material type, or material attribute. If “Attribute” is selected, the user can set a specific value for the attribute.
Advanced Options for the Contaminant Clean Rule Type
In order to remove this contaminant: Allows the user to define which contaminant the changeover will remove.
Advanced Options for the Default Rule Type
Also apply when material unchanged: Allows the user to enforce the changeover even when the prior and following order are producing the same material.
Advanced Options for the Line Mode Change Rule Type
From mode (blank for any): Allows the user to define the line mode that should exist prior to the changeover for the changeover to go into effect. Can be left blank to allow the changeover to accept any prior line mode.
To mode (blank for any):Allows the user to define the line mode that should exist after the changeover for the changeover to go into effect. Can be left blank to allow the changeover to accept any following line mode.
Test Changeovers
To ensure changeovers are created properly, you can make use of the Test Changeovers section of page.
Select the line from the drop-down. Select the “From material” and the “To material”. Click Get Changeover Rule. The rule Phenix will apply will appear on the right.
This feature is especially useful for rules that make use of Phenix Filtering Syntax, to ensure that the rule has been created properly to apply as intended.