Fastener Manufacturing & Thread Rolling worked example
Die Changeover Cost at 72% chargeable setup factor: a worked example in fastener manufacturing & thread rolling
Suppose chargeable setup factor falls to 72%. This page works the full calculation at that level so you can see exactly which result moves and by how much. Estimate die changeover cost from changeover hours, loaded labor or machine rate, chargeable factor, and fixed tooling expense.
The inputs for this scenario
- Die changeover time: 2.5 hr (held at the documented default)
- Loaded setup or machine rate: 145 $ / hr (held at the documented default)
- Chargeable setup factor: 72 % (the input this scenario stresses; the baseline uses 100)
- Fixed tooling or approval cost: 90 $ (held at the documented default)
Working through the calculation
- The calculation starts from the formula this tool documents: Die changeover cost = changeover time × loaded rate × chargeable factor + fixed tooling cost.
- Total die changeover cost works out to 351 $ at these inputs, and this is the headline figure for the scenario.
- Cost per changeover hour works out to 140 $ / hr at these inputs.
- Chargeable setup labor cost works out to 261 $ at these inputs.
- Fixed tooling or approval cost works out to 90 $ at these inputs.
How this compares with the baseline
- Against the tool's baseline example, where chargeable setup factor sits at 100% and the headline result is 453 $, this scenario comes in 22.43% below the baseline at 351 $.
- It computes the total cost of one die changeover by multiplying changeover time, loaded rate, and a chargeable factor, then adding fixed tooling or approval cost. 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
- Total die changeover cost: 351 $ (headline result)
- Cost per changeover hour: 140 $ / hr
- Chargeable setup labor cost: 261 $
- Fixed tooling or approval cost: 90 $
Run it with your numbers
- To rerun this with your own numbers, open the live Die Changeover Cost calculator, set chargeable setup factor to your actual value, and adjust the remaining inputs to match your operation.
Last reviewed 2026-05-12.