# Changeover Sequence Planning Worksheet

> Source: https://netray.co/tools/changeover-sequence-planning-worksheet
> Publisher: Netray (netray.co), AI and integration engineering for ERP and manufacturing systems.
> Section: Free Tools

## Short answer

List jobs in running order with setup and run minutes to see how much of the day is lost to changeovers and compare sequences.

## Category

mes-shop-floor

## Industry

Discrete Manufacturing

## Audience

- Production scheduler
- Planner
- Lean coordinator

## Tool

**Kind:** worksheet

**Mode:** editable

**Columns:**

#### Run order

**Key:** pos

**Type:** number

#### Job

**Key:** job

**Type:** text

#### Part family

**Key:** family

**Type:** select

**Options:**

- Small shaft
- Large shaft
- Housing
- Plate
- Bracket
- Other

#### Changeover min

**Key:** setup_min

**Type:** number

**Format:** number

#### Run min

**Key:** run_min

**Type:** number

**Format:** number

#### Units

**Key:** units

**Type:** number

**Format:** integer

#### Total min

**Key:** total_min

**Type:** number

**Expr:** setup_min + run_min

**Format:** number

#### Min per unit incl. setup

**Key:** min_unit

**Type:** number

**Expr:** (setup_min + run_min) / units

**Format:** decimal

**Rows:**

**Pos:** 1

**Job:** WO-2201

**Family:** Small shaft

**Setup min:** 40

**Run min:** 180

**Units:** 300

**Pos:** 2

**Job:** WO-2202

**Family:** Small shaft

**Setup min:** 10

**Run min:** 120

**Units:** 200

**Pos:** 3

**Job:** WO-2203

**Family:** Large shaft

**Setup min:** 55

**Run min:** 150

**Units:** 80

**Pos:** 4

**Job:** WO-2204

**Family:** Housing

**Setup min:** 75

**Run min:** 210

**Units:** 60

**Pos:** 5

**Job:** WO-2205

**Family:** Small shaft

**Setup min:** 45

**Run min:** 90

**Units:** 150

**Totals:**

#### Total changeover minutes

**Key:** setup_min

**Agg:** sum

**Format:** number

#### Total run minutes

**Key:** run_min

**Agg:** sum

**Format:** number

#### Total minutes

**Key:** total_min

**Agg:** sum

**Format:** number

**Summary:**

#### Changeover share of time

**Key:** setup_pct

**Expr:** sum_setup_min / sum_total_min * 100

**Format:** percent

**Primary:** true

#### Minutes saved if setups fall 20 percent

**Key:** saved

**Expr:** sum_setup_min * 0.2

**Format:** number

**Notes:** Make a copy of the sheet for each candidate sequence. In the example, running the third small shaft job straight after the first two would cut its changeover.

## Content

**Intro:** Changeovers are paid time with no output. This worksheet lets a scheduler lay out a running order, enter the changeover and run minutes for each job and compare sequences by the share of time lost.

**Sections:**

#### How to use it

**Body:** Enter jobs in the order you plan to run them. For each, record the changeover minutes from the previous job, not a generic routing setup, because a change within the same part family is far shorter than a change across families. Compare two or three sequences and keep the one with the lowest changeover share that still meets due dates. Export to Excel to keep the winning sequence with the schedule.

#### Sequence logic

**Body:** Sequence-dependent setups mean the best order is rarely first-in first-out. Group by family, tooling or material, and run from light to heavy or small to large when that avoids cleaning or re-fixturing. Then check the due dates. A grouped sequence that makes the most urgent job late is not an improvement. Use the summary to quantify the gain so the trade-off is explicit.

**Bullets:**

- Group by fixture, tooling or material first.
- Move urgent jobs forward only as far as needed.
- Review changeover actuals each week.

#### Reading the results

**Body:** The share of changeover time shows where improvement effort pays. If the share is high, a SMED effort on the worst family pair usually beats trying to run faster. Minutes per unit including setup shows why very small lots are expensive: the same 40 minute setup spread over 40 pieces adds a full minute to each.

#### Common mistakes

**Body:** Do not use the routing setup time for every job. Do not forget teardown or first piece approval, which many shops leave out of the number. Also avoid optimizing the sequence on a non-bottleneck machine; the saved minutes there may not become output.

**Cta:** If sequence-dependent setups are central to your scheduling, we can help extract changeover history from your ERP or MES and model better sequences.

**Faq:**

#### Is this a SMED worksheet?

**Answer:** No. It plans the order of jobs and totals changeover time. SMED reduces the length of each changeover. Use both: sequence first for quick gains, then reduce the worst changeovers.

#### What counts as changeover time?

**Answer:** From the last good piece of the previous job to the first good piece of the next, including teardown, setup, adjustment and first piece approval.

#### How do I record sequence-dependent setups?

**Answer:** Enter the changeover minutes for the actual pair of jobs in the sequence. Keep a separate matrix of family to family times if you plan often.

#### Can it sequence automatically?

**Answer:** No, it is a manual comparison sheet. Automatic sequencing needs an optimizer or an APS that holds the setup matrix.

## Search terms

changeover sequence template, changeover planning worksheet excel, setup sequence optimization sheet, product family sequencing worksheet, changeover time tracking template, production sequence planning excel, setup minutes per job worksheet, changeover matrix template

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