Advanced Planning, Scheduling & APS worked example

Changeover Sequence Savings at 98% realizable sequence savings: a worked example

What does the result look like when realizable sequence savings reaches 98%? The full calculation is worked below with real intermediate numbers. a master scheduler needs to show the benefit of resequencing jobs by setup family

The inputs for this scenario

  • Avoided changeovers per period: 14 changeovers (unchanged)
  • Fully loaded cost per changeover: 475 $ / changeover (unchanged)
  • Realizable sequence savings: 98 % (raised for this scenario; the documented default is 85)
  • Sequence planning effort adjustment: 650 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Gross sequence savings = avoided changeovers × cost per changeover × realizable sequence savings) to the inputs above produces each figure below.
  • At this operating point the engine returns 7,167 $ sequence savings for net changeover sequence savings, the number this scenario is built around.
  • At this operating point the engine returns 512 $ / changeover for cost per changeover.
  • At this operating point the engine returns 6,517 $ sequence savings for gross sequence savings.
  • At this operating point the engine returns 650 $ for sequence planning effort.

How this compares with the baseline

  • Against the tool's baseline example, where realizable sequence savings sits at 85% and the headline result is 6,303 $ sequence savings, this scenario comes in 13.72% above the baseline at 7,167 $ sequence savings.
  • A figure at this level is achievable when realizable sequence savings is genuinely sustained, not just peaked for a shift. It assumes your avoided-changeover count and cost-per-changeover are accurate; if those come from gut feel rather than time studies, the result inherits that error and can overstate savings.

Results at a glance

  • Net changeover sequence savings: 7,167 $ sequence savings (headline result)
  • Cost per changeover: 512 $ / changeover
  • Gross sequence savings: 6,517 $ sequence savings
  • Sequence planning effort: 650 $

Run it with your numbers

  • Every input above is editable in the live Changeover Sequence Savings calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.