Furniture, Fixtures & Interior Products worked example

Assembly Station Balance with assembled units in the run of 110 units: a worked example

Here is what the math looks like when conditions slip. We hold every other input steady and drop assembled units in the run to 110 units, then walk the calculation through step by step. Estimate assembly station cost and cost per assembled furniture or fixture unit while balancing work between stations.

The inputs for this scenario

  • Assembled units in the run: 110 units (the input this scenario stresses; the baseline uses 220)
  • Variable station cost per unit: 11.4 $ / unit (held at the documented default)
  • Station setup and fixture cost: 380 $ (held at the documented default)
  • Labor imbalance and overhead adder: 260 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Total assembly station cost = assembled units in the run × variable station cost per unit + station setup and fixture cost + labor imbalance and overhead adder.
  • Total assembly station cost works out to 1,894 $ at these inputs, and this is the headline figure for the scenario.
  • Cost per assembled unit works out to 17.22 $ / piece at these inputs.
  • Variable station cost per unit works out to 1,254 $ at these inputs.
  • Station setup and fixture cost plus Labor imbalance and overhead adder works out to 640 $ at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where assembled units in the run sits at 220 units and the headline result is 3,148 $, this scenario comes in 39.83% below the baseline at 1,894 $.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to assembled units in the run, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. The labor imbalance adder is an estimate of the cost of idle and waiting time; it's only as good as your line-balance study, so a rough adder gives a rough per-unit cost.

Results at a glance

  • Total assembly station cost: 1,894 $ (headline result)
  • Cost per assembled unit: 17.22 $ / piece
  • Variable station cost per unit: 1,254 $
  • Station setup and fixture cost plus Labor imbalance and overhead adder: 640 $

Run it with your numbers

  • To rerun this with your own numbers, open the live Assembly Station Balance calculator, set assembled units in the run to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.