Rüstkosten

Rüstkosten, also known as setup costs or changeover costs, are expenses incurred when a manufacturing production line or process is changed from producing one type of product to another. These costs are associated with the preparation and adjustment of machinery, tools, and other equipment necessary for the new production run. Examples of Rüstkosten include the labor required to disassemble old setups and assemble new ones, the cost of new tooling or fixtures, cleaning expenses, and any material scrap generated during the changeover period.

The concept of Rüstkosten is particularly relevant in industries with high product variety or frequent product changes, such as automotive manufacturing or consumer goods production. Minimizing Rüstkosten is a key objective in lean manufacturing and production efficiency strategies. Techniques like Single-Minute Exchange of Die (SMED) are specifically designed to drastically reduce the time and cost associated with these changeovers.

High Rüstkosten can lead to longer production runs to amortize the setup cost over a larger batch, which in turn can increase inventory levels and reduce manufacturing flexibility. Conversely, reducing Rüstkosten allows for smaller batch sizes, leading to greater responsiveness to market demand, reduced lead times, and lower work-in-progress inventory. Therefore, understanding and managing Rüstkosten is crucial for optimizing production planning and achieving overall operational excellence.