SMT Line Changeover and Feeder Setup Worksheet
SMT lines often lose more time to changeover than to placement. This worksheet turns the daily job list into a time-phased view of changeover, run time and total line minutes, so the planner can see whether the schedule fits and which sequence saves feeder loads.
| Job / WO | Assembly | Boards | Line rate (CPH) (cph) | Placements per board | New feeders to load | Min per feeder (min) | Fixed changeover (stencil, program, conveyor) (min) | Changeover time | Run time | Total job time | Changeover share | |
|---|---|---|---|---|---|---|---|---|---|---|---|---|
82 min | 260 min | 342 min | 24% | |||||||||
38 min | 259.2 min | 297.2 min | 12.8% | |||||||||
108 min | 267.4 min | 375.4 min | 28.8% | |||||||||
8 min | 172.8 min | 180.8 min | 4.4% |
CPH is your realistic line rate after accounting for feeder and nozzle pick time, not the machine nameplate. Reusing the same assembly back to back (WO-118204 above) drops changeover sharply because feeders stay loaded; sequence similar assemblies together to reduce setup. Add your own offline kitting and verification minutes into the fixed column.
Pull jobs from your ERP into the schedule
Optional: discuss reading work orders and routings straight from your ERP.
Optional. The tool and every export work without this. No spam.
How to use the worksheet
Enter one row per job in the order you plan to run it. For each job set the board quantity, the realistic placement rate in components per hour, and the placements per board. Then enter how many feeders must be newly loaded relative to the previous job and the average minutes per feeder, plus the fixed changeover for stencil, program load and conveyor width. The sheet calculates changeover, run time and total time per row, plus the changeover share of the whole schedule.
- Count only feeders that are not already on the machine.
- Use measured CPH, not nameplate speed.
- Add a row for first article time if you want it in the plan.
- Re-sort the rows to compare sequences by total minutes.
The method
Run time equals boards times placements per board divided by CPH, converted to minutes. Changeover equals new feeders times minutes per feeder plus fixed tasks. Total job time is the sum. The changeover share, setup divided by total, is the key lean metric: if it is above roughly 25 to 30 percent on a high mix line, single minute exchange of die (SMED) style work such as offline feeder prep, preloaded feeder carts and common feeder families will pay back quickly.
Reading the example
The small run of 120 boards at 520 placements per board needs 52 new feeders and takes far more time in changeover than in placement. The 400 board repeat run that follows WO-118202 needs no new feeders and only 8 fixed minutes, so almost all of its time is productive. The planner can use the total to decide whether the four jobs fit into a shift or whether the second job should be moved next to a similar assembly.
Common mistakes
Planners often use the machine's rated speed, which can be 40 to 60 percent higher than real line output on mixed packages. Others leave out the stencil clean, first article inspection and SPI check from changeover, which hides real lost time. Keep the columns honest and review actual versus planned minutes weekly; the gap tells you where to improve.
Frequently Asked Questions
What is a good CPH for planning?
Use the measured average output from recent runs of similar assemblies, usually 50 to 80 percent of the machine's rated speed depending on the package mix and board size. Rated speeds are measured under ideal conditions that rarely apply to real jobs.
How do I reduce SMT changeover time?
Prepare feeders and kits offline while the previous job runs, standardize feeder positions for common parts, sequence similar assemblies together and use feeder carts. Moving tasks from internal (line stopped) to external (line running) is the core SMED idea.
Does this include yield loss?
No. It estimates time only. If you have a measurable scrap or rework rate, add it by increasing the board quantity or by adding extra time per job for rework.
Can I use it for multiple lines?
Yes. Duplicate the worksheet or add a line column in your Excel export and total each line separately. This tool assumes one line's job sequence.
If your work orders and routings are in an ERP, we can read them directly and build this schedule view with real quantities and feeder data on your own infrastructure.
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