Setup Time Reduction Research Articles

Energy-aware scheduling in flow shops: a novel artificial neural network-driven multi-objective optimization

Group technology is a managerial strategy used to optimize production by reducing setup times, lead times, and work-in-process inventories. Research on flow-shop sequence-dependent group scheduling problems (FSDGSPs) has primarily focused on minimizing makespan and total flow time to improve efficiency. However, the need for energy-efficient scheduling in FSDGSPs remains underexplored despite increasing sustainability concerns. To address this, the energy-efficient flow-shop sequence-dependent group scheduling problem (EEFSDGSP) is introduced. A novel multi-objective optimization (MOO) technique, the artificial neural network-based multi-objective genetic algorithm (ANN-MOGA), is proposed to minimize makespan and energy consumption in EEFSDGSP. ANN-MOGA advances MOO by using a neural network to evaluate fitness and guide selection, reducing computational complexity versus traditional methods like NSGA-II and SPEA2. A post-processing step (PPANNS) further enhances solution diversity and distribution. Results show ANN-MOGA, especially with PPANNS, outperforms NSGA-II and competes effectively with SPEA2 in larger problem instances.

6-DOFs Robot Placement Based on the Multi-Criteria Procedure for Industrial Applications

Robot acceptance is rapidly increasing in many different industrial applications. The advancement of production systems and machines requires addressing the productivity complexity and flexibility of current manufacturing processes in quasi-real time. Nowadays, robot placement is still achieved via industrial practices based on the expertise of the workers and technicians, with the adoption of offline expensive software that demands time-consuming simulations, detailed time-and-motion mapping activities, and high competencies. Current challenges have been addressed mainly via path planning or robot-to-workpiece location optimization. Numerous solutions, from analytical to physical-based and data-driven formulation, have been discussed in the literature to solve these challenges. In this context, the machine learning approach has proven its superior performance. Nevertheless, the industrial environment is complex to model, generating extra training effort and making the learning procedure, in some cases, inefficient. The industrial problems concern workstation productivity; path-constrained minimal-time motions, considering the actuator’s torque limits; followed by robot vibration and the reduction in its accuracy and lifetime. This paper presents a procedure to find the robot base location for a prescribed task within the robot’s workspace, complying with multiple criteria. The proposed hybrid procedure includes analytical, physical-based, and data-driven modeling to solve the optimization problem. The contribution of the algorithm, for a given user-defined task, is the search for the best robot base location that enables the target points, maximizing the manipulability, avoiding singularities, and minimizing energy consumption. Firstly, the established method was verified using an anthropomorphic robot that considers different levels of a priori kinematics and system dynamics knowledge. The feasibility of the proposed method was evaluated through various simulations for small- and medium-sized robots. Then, a commercial offline program was compared, considering three scenarios and fourteen robots demonstrating an energy reduction in the 7.6–13.2% range. Moreover, the unknown joint dependency in real robot applications was investigated. From 11 robot positions for each active joint, a direct kinematic was appraised with an automatic DH scheme that generates the 3D workspace with an RMSE lower than 65.0 µm. Then, the inverse kinematic was computed using an ANN technique tuned with a genetic algorithm showing an RMSE in an S-shape task close to 702.0 µm. Finally, three experimental campaigns were performed with a set of tasks, repetitions, end-effector velocity, and payloads. The energy consumption reduction was observed in the 12.7–22.9% range. Consequently, the proposed procedure supports the reduction in workstation setup time and energy saving during industrial operations.

Reduction of Setup Times in a Metal Fabrication Company Using a Lean-Sigma Approach

Manufacturing companies face demand fluctuations and must deliver the required quantity of parts to their customers within the required time; however, companies face different challenges in fulfilling them. One is technological advances, which make it impossible for them to compete with other countries, such as China, due to financial issues. Therefore, manufacturing companies use continuous improvement methodologies to achieve better performance in their processes. Six Sigma and Lean Manufacturing are some of the best-known approaches. This article briefly presents the application of a lean sigma approach oriented to solving problems. This research proposes a methodology based on Lean Sigma that contrasts what different authors currently do: continuous improvement projects that take up to 12 months to produce results and do not solve a problem. This implementation is conducted in a process that manufactures metal parts and fails to deliver them on time to its customers. Using tools such as the Single Minute Exchange of Die (SMED) in a production line, on-time deliveries were increased from 89 % to 96 %; at the same time, the model change times were reduced by approximately 60 %, which is required for the implementation of this methodology for only four weeks, unlike the traditional six-sigma approach that can take up to 12 months to improve the process.

Optimisation of the Partial Runner Set-up Process in Plastic Injection Moulds Using Eight Steps in the Motorcycle Industry

Purpose: This study aims to analyse the causes of partial set-up work that is not optimal and provide solutions to the sub-optimal set-up work on family-type moulds in type A. Methodology/Approach: This study uses an 8-Step improvement approach combined with several methods, including Focus Group Discussion (FGD), Quality Cost Delivery Safety Moral (QCDSM), and Specific Measurable Achievable Relevant Timebase (SMART) method. Findings: This study found the cause of the partial set-up work being less than optimal due to problems with the Man, Method, and Machine factors. The results of this study show that the set-up time decreased from 240 minutes to 73.4 minutes or 68%. Meanwhile, the process cost for the partial set-up itself decreased from $75 to $3 or decreased by 97%. Research Limitation/implication: This research has limitations in the partial set-up process, which is less than optimal in plastic injection family-type moulds in the Motorcycle Industry. Originality/Value of paper: This research has value in optimising the production of plastic injection family-type moulds by reducing set-up time and operational costs for making spare parts in the Motorcycle Industry

Extraperitoneal robot assisted laparoscopic prostatectomy with Versius system: single centre experience.

Versius Surgical System (CMR Surgical, Cambridge, UK) is a novel tele-operated robotic surgical system designed to assist surgeons for minimally invasive surgery which is gaining momentum in the world of robotic surgery. We describe our single centre experience with Versius and report the advantages and challenges posed by this new robotic system in a series of 53 extraperitoneal robotic assisted laparoscopic prostatectomies (eRALP) for prostate cancer (PCa). Data of 53 eRALP performed with Versius in our centre were collected and analysed, Descriptive statistics were used to report our results. In 16 months we performed 53 eRALP: 18 (34%) with PLND, 33 (62%) nerve sparingcases. Mean setup time was 15 min, mean console time was 100 min and mean operative time was 130 min. We observed a substantial reduction of console time and set-up time after only 5 procedures. In the first 4 procedures, the dissection of the neurovascular bundle was performed laparoscopically, to switch back to robotic assisted approach afterwards. No major system failures were observed. No major intra-operative and post-operative complications occurred. Mean follow-up time was 9 months (range 3-15 months); no patients experienced biochemical recurrence or metastatic progression over this period, 8 (15%) patients had adjuvant radiotherapy based on unfavourable pathology report (positive surgical margins or positive limphnodes). This represents to our knowledge the largest extraperitoneal RALP case series with Versius, and it aims to provide solid clinical proof of the safety, effectiveness and versatility of this innovative system. In our experience, this platform represents a good option for every urologic surgeon who wants to start a robotic programme and it appears particularly suitable for urologists with a large laparoscopic expertise.

Setup Time Reduction for Toothpaste Tube Filling Machine: A Case Study of a Contract Toothpaste Manufacturing Company

This research aimed to find ways to reduce the idle time and improve the toothpaste tube filling machine setup procedure. The toothpaste manufacturing industry has many kinds of products nowadays, so the production process would need to frequently change its production plan, thus causing the number of machine setup times to increase. As such, the toothpaste tube filling machine would be unable to run simultaneously. According to the study, the average machine setup time on the filling machine was 157.1 minutes per time. This was more than the planned machine setup time of about 67.1 minutes, or 74.55 percent. The researchers presented the single-minute exchange of die and the eliminate, combine, reduce, and simplify approaches to reduce the average time of the machine setting by about 124.6 minutes per time, or 20.69 percent. The evaluation results of the process performance before and after the improvement by measuring the overall equipment efficiency from 41.66 percent to 58.61 percent increased by 16.95 percent.

Design, Fabrication, and Analysis of a Precision Drilling Jig for Waste Reduction: A Low-cost Solution

The modern assemblies of various machines such as engines, gears trains, and body panels require a highly precise drilling operation. These precisely drilled holes not only ensure the efficiency by constrained motions of these machines’ parts but also ensure longer service life. Moreover, precision drilling shall also ensure no subsequent requirement of reaming resulting in time and cost-saving. The precise drilling operation cannot be achieved unless highly precise machinery (CNC) is being utilized requiring higher initial investment (Pkr 1000000), or highly skilled workers demanding about twice the labor than the semi-skilled person. Being a small-sized industry, for profitability, a low-cost solution was proposed in this current work. To obtain precise drilling operation by the application of a drilling jig (Pkr 3000) on the manual bench drill machine (Pkr 15000), by a semi-skilled worker. In this work, a drilling jig has been designed, fabricated, and analyzed. This jig also can rotate the workpiece in clockwise/counter-clockwise directions. The drilled holes measurements provided the evidence that under the spindle speeds of 340, 700, and 1000 rpm, the closer dimensional values (~0.1mm) can be obtained, resulting in the elimination of rework and extra cost, along with the setup-time reduction by eliminating marking and center punching process, with the application of jig. It was concluded that the jig is quite applicable and can be substituted with high-cost CNC machines as a low-cost solution to the local small and medium-scale manufacturing industries.

Using the Single Minute Exchange of Die (SMED) Method to Minimize Machine Setup Time: A Case Study

PT. GTC is a company that produces automobile tubes facing problems with an increase in demand of up to 20% from the previous year. From 4 existing divisions named mixing, extruding, splicing, and curing, it was found that the extruding division was unable to meet the production targets set by the company. There are several causes, including high setup time. This research aims to reduce setup time by applying the Single Minute Exchange of Die (SMED) method to the production process in the extruding machine-1 that produces automobile tube sizes 5.50-13 and 7.00-14. Converting activities no. 2, 3, and 14 from internal activities to external activities, changing the layout of the die, core, and adjuster key storage table, dies unification, and installing a Temperature Control Unit to control steam to the extruder head can reduce setup time from 45 minutes to 22 minutes or 51% from the initial setup time. These improvements succeeded in increasing the productivity of the extruding division up to 93.9% in January 2023. Keywords: single-minute exchange of die, SMED, setup time, production achievement, unification

Penerapan Lean Manufacturing untuk Meminimasi Proses Dandori Mesin Molding Pada PT XYZ dengan Metode SMED

PT XYZ is a manufacturing company that produces various products, such as molds and several spare parts. The production process often experiences wasted time at the machine setup stage, known as dandori. To avoid production delays, companies need to increase their productivity. This research aims to propose the application of Lean Manufacturing methods, especially SMED, to reduce machine uptime by focusing on optimizing external activities in mold making. Through the application of the Single Minute Exchange of Dies (SMED) concept, fourteen internal activities were changed to eight internal activities, resulting in improvements with a reduction in machine setup time from 44 minutes to 22 minutes, or a reduction of 50%. The hope is that these results will increase the company's output significantly.

"Harnessing the Power of Artificial Intelligence in Flexible Manufacturing Systems: Enhancing Efficiency, Adaptability, and Competitiveness"

A promising paradigm in contemporary manufacturing is the fusion of Artificial Intelligence (AI) technology with Flexible Manufacturing Systems (FMS). FMS, characterized by their ability to adapt to dynamic production demands, have found a perfect ally in AI, which offers advanced capabilities in data analysis, decision-making, and process optimization. This abstract provides an overview of the synergistic relationship between AI and FMS and highlights the potential benefits and challenges associated with their integration. Firstly, this abstract explores the role of AI in FMS, focusing on three key areas: planning and scheduling, intelligent control, and predictive maintenance. FMS is equipped with AI technologies like machine learning and deep learning to quickly analyze massive amounts of data, spot trends, and make precise predictions. These capabilities enhance production planning by optimizing resource allocation, reducing setup time, and minimizing production downtime. Additionally, intelligent control systems powered by AI enable real-time adjustments in response to changing conditions, leading to improved system flexibility, agility, and responsiveness. Due to a number of strong arguments, the combination of Flexible Manufacturing Systems (FMS) with Artificial Intelligence (AI) is of great research significance. The research significance of combining AI with Flexible Manufacturing Systems lies in the potential to significantly enhance operational efficiency, adaptability, and decision-making capabilities in manufacturing. This integration enables manufacturers to optimize resource utilization, mitigate downtime, and proactively manage maintenance, ultimately leading to improved productivity, cost savings, and competitiveness. By addressing the challenges and exploring the opportunities offered by AI in FMS, researchers can contribute to the advancement and transformation of the manufacturing industry. Due to the abundance of possibilities offered on the global market, conflicting situations can develop while choosing a certain motorcycle. There may be many alternatives to the initial choice or there may not always be a fixed amount of possibilities available. The possibility of not having an acceptable option for the criterion exists as well. “Multiple Criteria Decision Making” is a technique designed for the optimization of problems with an “infinite or finite number of choices” and the MCDM technique. “WSM method” is used to optimize the process in this paper. In artificial intelligence with flexible manufacturing system evaluated six criteria and got the values. in that values .FMS 1 has got the first rank, FMS 2 got the second rank,FMS 3 got the third rank and FMS 4 got the last rank.In conclusion, the integration of AI with Flexible Manufacturing Systems offers numerous opportunities for enhanced operational efficiency, productivity, and adaptability.

Reduction in setup time for the POLO part on the MAUSA B CNC machine

With the increasing demand for industries to enhance production at reduced costs while minimizing lead time, adopting efficient tools and techniques to optimize the manufacturing process has become crucial. The primary objective of this study was to boost productivity and simplify the entire setup process for the Polo component on a MAUSA B CNC machine by introducing the SMED (Single Minute Exchange of Die) approach, which aims to minimize machine and tool setup duration. The process in question has a lengthy manufacturing cycle, necessitating the implementation of sophisticated approaches to achieve substantial outcomes in reducing the cycle. Additionally, the process requires well-structured planning, which differs from serial processes where minor solutions can yield significant benefits in terms of cost and production cycle reduction. This article outlines the solutions and enhancements utilized in the process.

Reduksi Waktu Set up Pekerjaan Penggantian Ban Sepeda Motor dengan Metode Single Minute Exchange of Dies

Currently, almost every household in Indonesia has a motorbike, this is certainly a business opportunity. One of the most important components of a motorbike is the tire which functions to reduce vibration and protect the wheel from wear and damage. The business environment operating in the automotive sector needs to create high-quality goods or services to increase customer satisfaction. Costs in the company's productive processes must be reduced to achieve effectiveness. The object of this research is the XYZ Tire Workshop located in East Jakarta. In a day, the XYZ Ban workshop can provide up to 25 to 30 motorbike tire changes. Meanwhile, the workforce on duty is only 2 mechanics and the quantity of tools is limited. This causes delays and makes customers have to wait quite a long time before their motorbike can be worked on. The Single Minute Exchange of Dies (SMED) method which is included in lean tools is the key to reducing set-up process time. In general, SMED aims to standardize and simplify operating processes. The SMED technique is used as an element in Total Productivity Maintenance (TPM) in various studies to achieve lean manufacturing. Based on research data, the set-up time before implementing SMED was 177 seconds. After implementing the SMED method, the setup time was 126 seconds. This shows that the SMED method can reduce set-up time by 51 seconds.

Prospective Evaluation of Implementation of a Tattoo-less Workflow for Non-Spine Bone SBRT

Oligometastatic disease has expanded the clinical indications for non-spine bone (NSB) SBRT. Optical surface monitoring systems (OSMS) may reduce treatment time if it represents an effective surrogate for bone intrafraction motion monitoring. We aimed to identify whether OSMS could substitute for 2D-3D mid-imaging and enable a tattoo-less set up in NSB SBRT. Beginning 11/2019, OSMS was incorporated in parallel with an existing workflow using CBCT and mid 2D-3D kV/kV imaging for pre- and mid-imaging for NSB SBRT. The ability of OSMS to detect both observed out-of-tolerance (>2mm/>2deg) shifts and manual couch shifts was analyzed. A workflow incorporating OSMS reference captures, CBCT for pre-treatment verification and OSMS/triggered imaging (TI) for intrafraction monitoring was developed and deployed for rib/sternum SBRT beginning 11/2021 and all NSB SBRT beginning 2/2022. All NSB SBRT treatment appointments were analyzed through statistical process control (SPC) with use of an XmR chart of average set up and total treatment time per quarter from 2/2019 to 2/2023. Special cause rules were based on IHI rules and conduced with spreadsheet software. From 2/2019 to 2/2023, 1962 NSB SBRT fractions were delivered, including 337 rib, 150 sternum, 197 femur, 266 ilium, 222 multi-site. Over 104 femur and 87 ilium images, there were no over tolerance intra-fraction events detected with 2D-3D or OSMS. Over 20 manual shifts, OSMS could detect 2mm shifts to within 0.4mm 67% of the time and 0.8mm 95% of time. There was no difference in treatment set up time following adoption of an OSMS/TI workflow as a replacement for 2D-3D mid-imaging. A reduction in rib SBRT delivery and multi-site treatment set-up times was significantly associated with the adoption of OSMS/TI and OSMS, respectively, as assessed based on special cause variation with 8 consecutive points below the mean. Integration of OSMS and triggered imaging has enabled the transition to a completely tattoo-less workflow, thus sparing patients the need for permanent tattoos whilst also allowing more continuous motion monitoring and reduced radiation exposure related to unnecessary 2D-3D or CBCT mid-imaging. Treatment times were significantly reduced for patients receiving rib SBRT or multi-site NSB SBRT with this workflow.

Setup Time Reduction of an Automotive Parts Assembly Line Using Lean Tools and Quality Tools

The business world is becoming more competitive. Therefore, it is crucial to increase the flexibility of production by decreasing the time used in the processes of preparing the production lines for new items’ production, reducing changeover and setup times. This paper presents a case study where the main goal is to reduce the setup time of welding robots. Single Minute Exchange of Die (SMED) was implemented, using other tools such as the Spaghetti Diagram, ERCS Analysis (Eliminate, Rearrange, Combine, Simplify), Gemba Walk, Standardized Work, Flowcharts, and Pareto Diagram. The setup time decreased by 36% in the welding robots studied, decreasing the motions by 43% during the changeover process and reducing the time from the categories: “transportation”, “main”, “other”, and “waiting”. In addition to SMED implementation, this study offers an integrated study of several Lean tools and Quality tools to achieve the maximum reduction of changeover and setup times.

The impact of lean production on sustainable organizational performance: the moderating effect of industry 4.0 technologies adoption

PurposeA paradigm shift of industry revolution 4.0 is made possible by technological advances that constitute a reversal of conventional lean production (LP) processes. In addition, there is increasing pressure on the manufacturing industry to manage operations responsibly towards the environmental and social impact, on top of the economic. These have motivated the manufacturing industry to identify approaches to implementing LP to achieve sustainable organizational performance. Hence, this study aims to examine the moderating role of industry 4.0 technologies adoption in the relationship between LP and sustainable organizational performance.Design/methodology/approachThis study proposed a research framework on the relationship between LP and sustainable organizational performance supported by LP theory and triple bottom line theory, with industry 4.0 technologies adoption as a moderator. A quantitative survey method was used in this study for data collection. The respondents in this study were middle or top management in manufacturing companies, including directors, managers, supervisors and coordinators. To investigate the demographic variables of respondents, descriptive statistics were generated by using IBM Statistical Packages for the Social Sciences. For measurement and structural model evaluations, partial least square structural equation modelling was used.FindingsBased on the proposed research framework in this study, supplier feedback, just-in-time delivery, supplier development, customer involvement, pull system, continuous flow, set-up time reduction (STR), statistical process control, total productive maintenance (TPM) and employee involvement are the dimensions for LP. This study revealed that industry 4.0 technologies adoption positively moderated the relationships of five LP dimensions towards a sustainable organizational performance, namely, supplier feedback, supplier development, continuous flow, STR and TPM.Originality/valueThis study provided insights that would enable practitioners to better strategize the co-existence of LP and industry 4.0 technologies adoption in mutually supporting sustainable organizational performance (environmental, social and economic).

Lean Practices, Perceived Environmental Uncertainty, and Business Performance: a Quantitative Study of Smes in Thailand

Purpose: The objective of this study was to investigate the moderating role of environmental uncertainty (EU) on the relationship between lean practices (LP) and business performance (BP) in SMEs in Thailand. Design/methodology/approach: The 170 samples of middle management level persons who were aware of lean concepts or practices from 120 manufacturing companies of SMEs in Thailand. We analyzed the relationship between lean practices and business performance by multiple linear regression analysis (MLR). Findings: The results revealed that performance uncertainty and process uncertainty have a significant impact on lean practices with a direct and negative effect. For the key performance result, the results revealed that only Statistical Process Control (SPC) and employee involvement (EI) of lean practices have a significant impact on the key performance result with a direct and positive significantly impactful, the results revealed that only Just in Time or JIT and Statistical Process Control (SPC) have a significant impact on the customer result control direct and positive effect. For the employee result, the results revealed that four dimensions of Lean Practices including supplier development or SD, Setup Time Reduction (STR), employee involvement, and Total Productive Maintenance (TPM) have a significant impact on the employee result with direct and positive effect. Research, Practical & Social Implications: This study provides lean practices in SMEs in Thailand and their moderating role on environmental uncertainty on the relationship between lean practices and business performance which in contributes to economic Thailand. Further research should focus on specific industries. Originality/value: Research moderating role of environmental uncertainty (EU) on the relationship between lean practices (LP) and business performance (BP) in SMEs in Thailand are especially important in SMEs.

Who Drives Circularity?—The Role of Construction Company Employees in Achieving High Circular Economy Efficiency

The circular economy in the construction industry is still in its infancy. It seems particularly difficult for companies in this sector to make strategic decisions that enable sustainable operations and ensure long-term business success. This article investigates factors such as employee involvement at the operational level that facilitate circular economy practices for companies in the construction industry. For this purpose, we conducted a company survey and analyzed it using a structural equation model. The results show that it is worthwhile for companies to empower their manufacturing employees to take actions independently in order to increase process quality and to reduce setup time, which together lead to better circular economy efficiency.

Precision Measurement of Complex Optics Using a Scanning-Point Multiwavelength Interferometer Operating in the Visible Domain

The growing demands of optical systems have led to increasingly complex aspheres and freeforms. In this paper, an established measurement system in asphere production, which is also a promising approach in high-precision freeform metrology, is presented. It is based on a scanning-point multiwavelength interferometer approach. The scanning principle enables great flexibility, reduces setup time and costs, and has almost no limitations in spherical departure. Due to the absolute measurement capability, the utilized multiwavelength approach is beneficial for segmented, annular, and discrete surfaces, which are common designs of modern applications’ optical elements. The metrology system enables measurements on a nanometer scale on a great variety of apertures—from 1 to 1000 mm. Recently, a new short-coherence multiwavelength interferometer operating in the visible domain has been developed. It enables the high-precision measurement on silicon-coated surfaces, which can be found in space applications and are also commonly used for extreme-ultraviolet (EUV) lithographic setups, which will be used as an example throughout this work. Owing to the large absolute measurement capability, applied grating structures for suppressing infrared light in the EUV process can easily be measured. This paper summarizes the basic working principles of the proposed metrology system, explains the special requirements for different fields of application, highlights the capabilities of the visible multiwavelength approach, and shows the measurement results.

ANALISIS PENURUNAN WAKTU SETUP DENGAN MENGGUNAKAN SINGLE MINUTE EXCHANGE OF DIE UNTUK MENINGKATKAN PRODUKTIVITAS PADA AUTOMATIC MOULDING MACHINE

PT XYZ is a company that has been engaged in metal casting for a long time. This company produces products in the form of wingnut spare parts. The production system used is make to order production. The obstacle faced by PT XYZ was that it was found that the setup operation process activity took quite a long time on average 40 minutes. If it continues to occur it will have an impact on delays. With these problems, PT XYZ reduced the setup time to overcome delays in completing the automatic molding machine wingnut product. Utilize the Single minute exchange of die (SMED) method to speed up setup. The SMED approach distinguishes between internal regulatory and external regulatory activities. Adjustment activities that only Internal adjustments can be made while the machine is stopped. The External Setup setup activity can be performed while the machine is running or operating. By switching to external setup instead of internal setup, setup tasks that were completed when the machine was stopped can now be completed while it is running, thereby reducing setup time. the setup operation of all these activities is carried out when the engine is off or the internal setup produces an average of 101 molds. Meanwhile, the setup time after implementing SMED can be reduced to 26.78 minutes or a decrease of 47.61%. This decrease in setup time increases productivity by 2 molds/day and if in a month with 26 working days it can add 59 molds so that in total it can produce 159 molds/month.

Simulation-based setting suggestions for yarn winding units to reduce color variation in knitted fabric

The finishing of yarns by bobbin dyeing is of key importance in the value chain of home and apparel textiles. In the bobbin dyeing process, yarn bobbins are placed on dye spindles and passed through with dye liquor. If the winding process parameters are selected unfavorably, the density of the winding package is inhomogeneous. The inhomogeneous density distribution leads to an inhomogeneous flow of dye liquid through the package and, hence, to dyeing defects. In order to minimize dyeing defects and to reduce set-up times, we present a simulation-based parameter recommendation for cross-winding machines in this paper. We use a kinematic model of the winding process combined with an empirical model for the package diameter to optimize the package density distribution. We introduce a criterion to avoid patterning defects and adapt winding settings. For bobbins with Nm 34 Co yarn, the homogeneity of the density was improved and the color deviation was reduced by up to 50% due to these simulation-based setting suggestions.