What this calculator does
This calculator estimates the annual effect of reducing elapsed changeover time. It values recovered production contribution and labour time for the entered number of changes. Use a separate quality check to ensure the faster method still reaches a stable first good pack.
Enter your figures and select calculate.
Planning estimate: Annual hours saved = (current minutes − improved minutes) × changes per week × working weeks ÷ 60. Annual value = hours saved × production contribution per hour + labour hours saved × labour rate.
Measure last good pack to stable first good pack
Include product removal, cleaning, line clearance, parts, settings, startup and first-off inspection.
- Use representative changeovers
- Record waiting and adjustment
- Track quality after restart
Value recovered time carefully
Production contribution should be included only when the line is capacity constrained or the time has a real use. Labour value depends on whether people are released or redeployed.
- Separate elapsed time and labour hours
- Use contribution not revenue
- Model high and low change frequency
Use the result to justify practical improvement
Compare the value with carts, duplicate tooling, quick-release parts, recipes, scales, training or engineering change.
- Start with external preparation
- Remove search and waiting
- Standardise the approved sequence