Foundry & Forging worked example

Die Changeover Loss at 110% changeover cost allocation: a worked example in foundry & forging

This scenario runs the die changeover loss calculation on the strong side: 110% changeover cost allocation, with every other input held at its documented default. Use it when changeover time, lost press capacity, warmup scrap, setup labor, and trial parts affect quote cost or schedule capacity.

The inputs for this scenario

  • Changeover events or lost hours: 6 events (unchanged)
  • Cost per changeover event: 950 $ / event (unchanged)
  • Changeover cost allocation: 110 % (raised for this scenario; the documented default is 100)
  • Fixed tooling setup cost: 1,200 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Total die changeover loss = changeover events or lost hours × cost per changeover event × changeover cost allocation + fixed tooling setup cost) to the inputs above produces each figure below.
  • At this operating point the engine returns 7,470 $ for total die changeover loss, the number this scenario is built around.
  • At this operating point the engine returns 1,245 $ / piece for die changeover loss per event.
  • At this operating point the engine returns 6,270 $ for variable die changeover loss.
  • At this operating point the engine returns 1,200 $ for fixed tooling setup cost.

How this compares with the baseline

  • Against the tool's baseline example, where changeover cost allocation sits at 100% and the headline result is 6,900 $, this scenario comes in 8.26% above the baseline at 7,470 $.
  • Use it when building a business case for quicker die changes, comparing run sizes, or allocating setup cost to a specific production order. Treat this as a target state: the delta against the baseline quantifies what the improvement is worth before you commit to chasing it.

Results at a glance

  • Total die changeover loss: 7,470 $ (headline result)
  • Die changeover loss per event: 1,245 $ / piece
  • Variable die changeover loss: 6,270 $
  • Fixed tooling setup cost: 1,200 $

Run it with your numbers

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

Last reviewed 2026-05-12.