Changeover Time

Changeover time — also called setup time or job change time — is the total elapsed time between the last good part of a finished production run and the first good part of the next. On a progressive header, changeover typically involves replacing dies, punches, transfer fingers, wire feed components, and re-adjusting all machine parameters for the new part geometry.

Why Changeover Time Matters

A progressive header that produces at 200 pcs/min but requires 8 hours of setup for every job change is far less productive than a machine producing at 150 pcs/min with 2-hour changeovers — particularly for job shops or manufacturers running frequent short production runs.

The OEE (Overall Equipment Effectiveness) of a forming line is directly affected by changeover time. Reducing setup from 6 hours to 2 hours on a machine running three part numbers per day adds up to over 1,000 hours of productive capacity per year.

What Makes Changeover Complex on a Progressive Header

A 5-station progressive header has:

• 5 die assemblies (each requiring removal, replacement, and pre-load adjustment)
• 5 punch assemblies (each requiring height and centering adjustment)
• 5 kickout pin positions (each requiring depth setting)
• Transfer finger sets (one set per station, gripping geometry matched to part diameter)
• Wire feed components (quill, cutter — sized to wire diameter)
• Machine settings: feed length, cutoff length, lubrication flows, speed

On traditional machines without a systematic setup recall system, each parameter must be re-established from scratch. Experienced operators often rely on handwritten notes or memory for settings from previous runs.

Systematic Approaches to Reducing Changeover

External Setup

All tooling is pre-assembled and pre-measured outside the machine — in a setup fixture — while the machine is still running the previous job. When the machine stops, only the final installation and adjustment remain.

Setup Recall Systems

Electronic storage of all machine settings under an article number. When the same part is run again, settings are recalled and the machine is configured to match the previous run — eliminating re-learning.

Positioning Indicators and Markers

Physical or electronic indicators on all adjustable components that show their correct position for a given setup. The operator sets each component to the indicated position rather than adjusting by trial and error.

Changeover on Manzoni Machines

The Read, Set & Go® system on Manzoni machines addresses changeover systematically:

• The complete machine setup — all station positions, kickout depths, feed length, all adjustable parameters — is stored in machine memory under an article number
• Electronic position displays at every adjustment point show the target position for the selected article
• Physical markers on mechanical components confirm position alignment
• The setup fixture for transfer fingers allows finger gripping geometry to be pre-set outside the machine

Because Manzoni machines use the Manzoni Absolute Zero Clearance® bearing system, punches are always aligned — no punch centering is needed at tool change. This step alone typically accounts for 30–60 minutes of setup time on machines with bronze liner guides.

The combination of Read, Set & Go®, zero-clearance alignment, and ergonomic machine design (low frame height, full accessibility of all adjustment points) means that even operators without prior experience with a specific part can set up the machine correctly.