ERP & MRP Planning worked example

Changeover Schedule Loss with planned changeover count of 9 changeovers: a worked example

Here is what the math looks like when conditions slip. We hold every other input steady and drop planned changeover count to 9 changeovers, then walk the calculation through step by step. Estimate schedule hours lost to planned changeovers from changeover count, average duration, affected resources, and sequence-loss factor.

The inputs for this scenario

  • Planned changeover count: 9 changeovers (the input this scenario stresses; the baseline uses 18)
  • Average changeover duration: 1.4 hr / changeover (held at the documented default)
  • Affected work-center count: 1 work centers (held at the documented default)
  • Sequence-loss multiplier: 1.15 x (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Changeover schedule loss = planned changeovers × average changeover duration × affected work centers × sequence-loss multiplier.
  • Changeover schedule loss works out to 14.49 hr at these inputs, and this is the headline figure for the scenario.
  • Base changeover hours before sequence loss works out to 12.6 hr at these inputs.
  • Sequence-loss multiplier works out to 1.15 x at these inputs.
  • Changeover count × duration works out to 12.6 hr at these inputs.

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 50% below the baseline at 14.49 hr.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to planned changeover count, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. It assumes an average changeover duration; in reality setups vary widely by job pairing, so a single sequence-dependent matrix gives a more accurate answer for complex shops.

Results at a glance

  • Changeover schedule loss: 14.49 hr (headline result)
  • Base changeover hours before sequence loss: 12.6 hr
  • Sequence-loss multiplier: 1.15 x
  • Changeover count × duration: 12.6 hr

Run it with your numbers

  • To rerun this with your own numbers, open the live Changeover Schedule Loss calculator, set planned changeover count to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.