ERP & MRP Planning worked example

Changeover Schedule Loss with planned changeover count of 45 changeovers: a worked example

Push planned changeover count up to 45 changeovers and the picture changes. This example computes every intermediate figure at that operating point. a scheduler needs to see how much capacity is lost to changeovers

The inputs for this scenario

  • Planned changeover count: 45 changeovers (raised for this scenario; the documented default is 18)
  • Average changeover duration: 1.4 hr / changeover (unchanged)
  • Affected work-center count: 1 work centers (unchanged)
  • Sequence-loss multiplier: 1.15 x (unchanged)

Working through the calculation

  • Applying the documented formula (Changeover schedule loss = planned changeovers × average changeover duration × affected work centers × sequence-loss multiplier) to the inputs above produces each figure below.
  • At this operating point the engine returns 72.45 hr for changeover schedule loss, the number this scenario is built around.
  • At this operating point the engine returns 63 hr for base changeover hours before sequence loss.
  • At this operating point the engine returns 1.15 x for sequence-loss multiplier.
  • At this operating point the engine returns 63 hr for changeover count × duration.

How this compares with the baseline

  • Against the tool's baseline example, where planned changeover count sits at 18 changeovers and the headline result is 28.98 hr, this scenario comes in 150% above the baseline at 72.45 hr.
  • It computes total scheduled hours lost to changeovers by multiplying the number of changeovers, their average duration, affected work centers and a sequence-loss multiplier. The value of this scenario is the size of the gap it exposes: that gap, priced out over a year, is the budget you can justify spending to close it.

Results at a glance

  • Changeover schedule loss: 72.45 hr (headline result)
  • Base changeover hours before sequence loss: 63 hr
  • Sequence-loss multiplier: 1.15 x
  • Changeover count × duration: 63 hr

Run it with your numbers

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

Last reviewed 2026-05-12.