Fastener Manufacturing & Thread Rolling worked example

Heading Press Output at 63% header efficiency after minor stops: a worked example

Here is what the math looks like when conditions slip. We hold every other input steady and drop header efficiency after minor stops to 63%, then walk the calculation through step by step. Estimate usable cold heading press output from completed blanks, run hours, and realistic press efficiency.

The inputs for this scenario

  • Good headed blanks completed: 24,000 pieces (held at the documented default)
  • Actual header run time: 8 hr (held at the documented default)
  • Header efficiency after minor stops: 63 % (the input this scenario stresses; the baseline uses 88)

Working through the calculation

  • The calculation starts from the formula this tool documents: Raw header rate = good headed blanks ÷ actual run time.
  • Effective header output works out to 1,890 units / hr at these inputs, and this is the headline figure for the scenario.
  • Raw header rate works out to 3,000 units / hr at these inputs.
  • Header efficiency works out to 63 % at these inputs.
  • Run time used works out to 8 hr at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where header efficiency after minor stops sits at 88% and the headline result is 2,640 units / hr, this scenario comes in 28.41% below the baseline at 1,890 units / hr.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to header efficiency after minor stops, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. It treats efficiency as a single flat factor, so it won't separate die-life-driven slowdowns from feed-related micro-stops — for root-cause work you still need an OEE breakdown by stop reason.

Results at a glance

  • Effective header output: 1,890 units / hr (headline result)
  • Raw header rate: 3,000 units / hr
  • Header efficiency: 63 %
  • Run time used: 8 hr

Run it with your numbers

  • To rerun this with your own numbers, open the live Heading Press Output calculator, set header efficiency after minor stops to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.