Tooling worked example

Changeover Reduction with current changeover of 190 min: a worked example

What does the result look like when current changeover reaches 190 min? The full calculation is worked below with real intermediate numbers. Use to justify SMED work, quick-change tooling, fixtures, or setup standardization.

The inputs for this scenario

  • Current changeover: 190 min (raised for this scenario; the documented default is 75)
  • Future changeover: 35 min (unchanged)
  • Changeovers per week: 8 events (unchanged)
  • Loaded labor rate: 42 $ / hr (unchanged)
  • Machine rate: 60 $ / hr (unchanged)
  • Output rate recovered: 90 units / hr (unchanged)
  • Production weeks: 50 weeks / yr (unchanged)

Working through the calculation

  • Applying the documented formula (Hours saved = (current − future minutes) × changeovers ÷ 60) to the inputs above produces each figure below.
  • At this operating point the engine returns 105,400 $ / yr for annual savings, the number this scenario is built around.
  • At this operating point the engine returns 1,033 hr / yr for hours recovered.
  • At this operating point the engine returns 155 min / changeover for minutes saved.
  • At this operating point the engine returns 93,000 units / yr for recovered output.

How this compares with the baseline

  • Against the tool's baseline example, where current changeover sits at 75 min and the headline result is 27,200 $ / yr, this scenario comes in 287% above the baseline at 105,400 $ / yr.
  • A figure at this level is achievable when current changeover is genuinely sustained, not just peaked for a shift. It assumes recovered hours are actually backfilled with sellable production; if the machine sits idle anyway, the capacity gain is theoretical, not realized cash.

Results at a glance

  • Annual savings: 105,400 $ / yr (headline result)
  • Hours recovered: 1,033 hr / yr
  • Minutes saved: 155 min / changeover
  • Recovered output: 93,000 units / yr

Run it with your numbers

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

Last reviewed 2026-05-12.