We have different container sizes (filling orders) for each bulk item. When we start with bulk item filling, we have a greater set-up effort than if we have to change the container size. The sequence of the containers can change with every new production run, we have to assume a worst-case scenario in the work schedules, which means full set-up time for bulk item filling.

Planning sequence could look like this:

Container A (filling order 1), Container B (filling order 2), Container C (filling order 3)

For the next new production of the bulk item, the planning sequence could look like this:

Container B (filling order 1), Container C (filling order 2)

Container A is not needed this time, so the full setup effort must be applied to container B, as well as a reduction in setup time for container C.

One way to realize this would be a setup matrix. As soon as the same bulk item appears in the parts list, time X- is used as the setup time or reduced by X-%. As soon as a change of bulk item occurs, 100% of the setup time is simply used in the routings.