Advanced Planning, Scheduling & APS worked example

Changeover Sequence Savings at 61% realizable sequence savings: a worked example

This worked example runs the changeover sequence savings numbers for a tougher week than the baseline: 61% realizable sequence savings instead of the typical 85%. Estimate savings from better job sequencing using avoided changeovers, cost per changeover, realizable savings share, and planning effort.

The inputs for this scenario

  • Avoided changeovers per period: 14 changeovers (held at the documented default)
  • Fully loaded cost per changeover: 475 $ / changeover (held at the documented default)
  • Realizable sequence savings: 61 % (the input this scenario stresses; the baseline uses 85)
  • Sequence planning effort adjustment: 650 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Gross sequence savings = avoided changeovers × cost per changeover × realizable sequence savings.
  • Net changeover sequence savings works out to 4,707 $ sequence savings at these inputs, and this is the headline figure for the scenario.
  • Cost per changeover works out to 336 $ / changeover at these inputs.
  • Gross sequence savings works out to 4,057 $ sequence savings at these inputs.
  • Sequence planning effort works out to 650 $ at these inputs.

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 25.32% below the baseline at 4,707 $ sequence savings.
  • Use it when evaluating an APS sequencing rule, a SMED initiative, or a family-batching policy, and you need to compare the savings against the scheduling effort to set it up. A result at this level usually justifies acting on the stressed input before touching anything else, because every other figure in the table is downstream of it.

Results at a glance

  • Net changeover sequence savings: 4,707 $ sequence savings (headline result)
  • Cost per changeover: 336 $ / changeover
  • Gross sequence savings: 4,057 $ sequence savings
  • Sequence planning effort: 650 $

Run it with your numbers

  • To rerun this with your own numbers, open the live Changeover Sequence Savings calculator, set realizable sequence savings to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.