On a shared packaging line, the order of runs matters as much as the runs themselves. Move from a strong flavor to a mild one and you need a deep clean. Move the other way and you may need almost none. Over a week of SKUs, the total changeover time can swing widely depending purely on sequence. Choosing the best order resembles the classic traveling salesman puzzle, and solvers handle it well. Planners can see how a sequencing solver reorders a real weekly run list and what it saves.
The Right Order of Runs Is Hidden Capacity
iFactory Dynamic Scheduler uses sequencing solvers to minimize total changeover time across a week of SKU runs on shared packaging lines.
One Set of SKUs, Two Different Routes
Each arrow is a changeover. A better route visits the same SKUs with less cleaning between them.
Schematic only. Real sequences involve many more SKUs and rules.
Where Changeover Time Goes
The sequence decides how much of each changeover type you pay for in a week.
Illustrative share of changeover time. Your own matrix gives the real split.
How the Solver Finds a Better Order
The method is systematic, not a guess.
Find the Changeover Time Hiding in Your Week
Share one week of SKU runs and your changeover matrix. We will compare your sequence with an optimized one.
Rules That Shape the Sequence
The shortest route is not always allowed. Rules decide what the solver may do.
| Rule | Example | Effect on Sequence |
|---|---|---|
| Allergen order | Run free-from before allergen products | Fixes the sequence of families |
| Light to dark | Mild flavors before strong ones | Reduces cleaning depth |
| Due dates | Orders must ship by a deadline | Limits how far runs can move |
| Cleaning windows | Deep clean once per shift | Groups products to share a clean |
Constraints Solvers Must Respect
A fast plan that breaks a rule is not a plan.
Quality constraints
Allergen, hygiene and traceability rules
Commercial constraints
Due dates and customer priorities
Operational constraints
Labor, tooling and shift ends
Hand Sequencing vs Solver Sequencing
Experienced planners do well on small lists. Complexity is where solvers help.
What Experienced Planners Look For in Sequencing
Frequently Asked Questions
How accurate must the changeover matrix be?
It should reflect actual cleaning and setup, not old standards. Even a rough matrix helps, but errors mislead the solver. Review your matrix with our team and fill the largest gaps first.
Can the solver handle allergen rules?
Yes. Allergen order is entered as a rule, so the solver only builds sequences that comply. Any rule you write down becomes part of the search.
What if a rush order breaks the plan?
The solver can re-sequence the remaining runs around the new order. See how a rush order reshapes a sequence in a live example.
Does the best sequence ever lose to due dates?
Sometimes. Due dates may force a longer path. The tool shows the trade-off so planners can choose with the numbers in front of them.
How much time can sequencing save?
It depends on your product mix and current practice. Plants with many SKUs and varied changeovers have more to gain. Estimate your own potential with a sample week on a call.
Run the Same Products in a Smarter Order
Bring your SKU list, a typical week and your changeover rules. We will show the sequence you have and the one you could have.
