Heat Treatment, Furnaces & Thermal Processing worked example

Load Thermocouple Workload at 14% tc setup allowance: a worked example

Here is what the math looks like when conditions slip. We hold every other input steady and drop tc setup allowance to 14%, then walk the calculation through step by step. Estimate load thermocouple setup and review time from thermocouple count, installation rate, and allowance.

The inputs for this scenario

  • Load thermocouples to prepare: 24 thermocouples (held at the documented default)
  • Thermocouple prep rate: 8 thermocouples / hr (held at the documented default)
  • TC setup allowance: 14 % (the input this scenario stresses; the baseline uses 20)

Working through the calculation

  • The calculation starts from the formula this tool documents: Base load thermocouple hours = load thermocouples to prepare รท thermocouple prep rate.
  • Required load thermocouple workload works out to 3.42 hr at these inputs, and this is the headline figure for the scenario.
  • Base thermocouple hours works out to 3 hr at these inputs.
  • TC setup allowance applied works out to 14 % at these inputs.
  • Thermocouple prep rate works out to 8 thermocouples / hr at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where tc setup allowance sits at 20% and the headline result is 3.6 hr, this scenario comes in 5% below the baseline at 3.42 hr.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to tc setup allowance, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. It assumes a steady prep rate; difficult attachment points, recalibration, or damaged TCs needing replacement can push actual time well past the estimate.

Results at a glance

  • Required load thermocouple workload: 3.42 hr (headline result)
  • Base thermocouple hours: 3 hr
  • TC setup allowance applied: 14 %
  • Thermocouple prep rate: 8 thermocouples / hr

Run it with your numbers

  • To rerun this with your own numbers, open the live Load Thermocouple Workload calculator, set tc setup allowance to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.