Changeover Capacity Loss Calculator

How the changeover capacity loss calculator works

Total changeover minutes equal changeover count times duration per change. Subtract that total from the scheduled window; the entered changes cannot consume more time than the window contains.

Each capacity is available minutes times 60 divided by constant cycle seconds, rounded down separately to whole units. Their difference is capacity consumed by those changeovers. Changeover share is unavailable at a zero scheduled window, which allows only zero changeover time.

This is an isolated time-loss comparison, not OEE, actual good output or a changeover improvement forecast. Other downtime, break periods, scrap, staffing constraints and overlap must be treated consistently outside this model.

Worked example

A 480-minute window contains three 20-minute changeovers, using 60 minutes or 12.5% of the window. At a 30-second cycle, capacity falls from 960 to 840 whole units, a difference of 120. Ten-minute changeovers instead consume 60 units of capacity.

Sources and assumptions

The source material explains the underlying calculation or pricing structure. Entered prices, costs, schedules and scenario choices are your assumptions; this tool does not obtain supplier quotes or predict actual results.

• Vorne: production time, stop losses and cycle relationships