Foundry & Forging worked example

Die Changeover Loss at 72% changeover cost allocation: a worked example in foundry & forging

This worked example runs the die changeover loss numbers for a tougher week than the baseline: 72% changeover cost allocation instead of the typical 100%. Estimate cost lost during forging die, die-casting die, trim die, or tooling changeovers.

The inputs for this scenario

  • Changeover events or lost hours: 6 events (held at the documented default)
  • Cost per changeover event: 950 $ / event (held at the documented default)
  • Changeover cost allocation: 72 % (the input this scenario stresses; the baseline uses 100)
  • Fixed tooling setup cost: 1,200 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Total die changeover loss = changeover events or lost hours × cost per changeover event × changeover cost allocation + fixed tooling setup cost.
  • Total die changeover loss works out to 5,304 $ at these inputs, and this is the headline figure for the scenario.
  • Die changeover loss per event works out to 884 $ / piece at these inputs.
  • Variable die changeover loss works out to 4,104 $ at these inputs.
  • Fixed tooling setup cost works out to 1,200 $ at these inputs.

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 23.13% below the baseline at 5,304 $.
  • Use it when building a business case for quicker die changes, comparing run sizes, or allocating setup cost to a specific production order. A result at this level usually justifies acting on the stressed input before touching anything else, because every other figure in the table is downstream of it.

Results at a glance

  • Total die changeover loss: 5,304 $ (headline result)
  • Die changeover loss per event: 884 $ / piece
  • Variable die changeover loss: 4,104 $
  • Fixed tooling setup cost: 1,200 $

Run it with your numbers

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

Last reviewed 2026-05-12.