Composites, Fiberglass & Advanced Materials worked example

Kitting Labor Load at 14% setup and shortage allowance: a worked example

Suppose setup and shortage allowance falls to 14%. This page works the full calculation at that level so you can see exactly which result moves and by how much. Estimate labor hours to kit fabric, prepreg plies, core, inserts, bagging consumables, and resin materials.

The inputs for this scenario

  • Composite kit line items to pull: 180 kit lines (held at the documented default)
  • Kit lines completed per hour: 24 kit lines / hr (held at the documented default)
  • Setup and shortage allowance: 14 % (the input this scenario stresses; the baseline uses 20)

Working through the calculation

  • The calculation starts from the formula this tool documents: Base kitting labor load = composite kit line items รท kitting completion pace.
  • estimated kitting labor load works out to 8.55 hr at these inputs, and this is the headline figure for the scenario.
  • base kitting labor load works out to 7.5 hr at these inputs.
  • kitting setup and shortage allowance works out to 14 % at these inputs.
  • kitting completion pace works out to 24 kit lines / hr at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where setup and shortage allowance sits at 20% and the headline result is 9 hr, this scenario comes in 5% below the baseline at 8.55 hr.
  • It computes the total labor hours to pick and stage a composite kit by dividing kit line items by hourly picking pace, then adding a percentage for setup and shortage handling. When the numbers land here, the stressed input is the lever to work; the walkthrough above shows exactly how much each output recovers as it climbs back toward the baseline.

Results at a glance

  • estimated kitting labor load: 8.55 hr (headline result)
  • base kitting labor load: 7.5 hr
  • kitting setup and shortage allowance: 14 %
  • kitting completion pace: 24 kit lines / hr

Run it with your numbers

  • To rerun this with your own numbers, open the live Kitting Labor Load calculator, set setup and shortage allowance to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.