Heat Treatment, Furnaces & Thermal Processing worked example
Thermal Recipe Changeover at 98% setup window uptime: a worked example
Push setup window uptime up to 98% and the picture changes. This example computes every intermediate figure at that operating point. Use it when switching furnace temperature, atmosphere, belt speed, vacuum recipe, or controller program can limit production flow.
The inputs for this scenario
- Recipe changeovers per setup cycle: 1 changeovers / cycle (unchanged)
- Available setup cycles per shift: 6 cycles / shift (unchanged)
- Setup window uptime: 98 % (raised for this scenario; the documented default is 85)
- First-pass recipe setup yield: 95 % (unchanged)
Working through the calculation
- Applying the documented formula (Gross recipe changeover capacity = changeovers per setup cycle × available setup cycles) to the inputs above produces each figure below.
- At this operating point the engine returns 5.59 qualified changeovers / shift for qualified recipe changeover capacity, the number this scenario is built around.
- At this operating point the engine returns 6 qualified changeovers / shift for gross changeover capacity.
- At this operating point the engine returns 0.12 qualified changeovers / shift for setup downtime loss.
- At this operating point the engine returns 0.29 qualified changeovers / shift for recipe setup yield loss.
How this compares with the baseline
- Against the tool's baseline example, where setup window uptime sits at 85% and the headline result is 4.85 qualified changeovers / shift, this scenario comes in 15.29% above the baseline at 5.59 qualified changeovers / shift.
- It computes how many recipe changeovers per shift will actually qualify, after derating gross capacity for setup-window uptime and first-pass setup yield. The value of this scenario is the size of the gap it exposes: that gap, priced out over a year, is the budget you can justify spending to close it.
Results at a glance
- Qualified recipe changeover capacity: 5.59 qualified changeovers / shift (headline result)
- Gross changeover capacity: 6 qualified changeovers / shift
- Setup downtime loss: 0.12 qualified changeovers / shift
- Recipe setup yield loss: 0.29 qualified changeovers / shift
Run it with your numbers
- Every input above is editable in the live Thermal Recipe Changeover calculator, which recalculates instantly and can be shared with the inputs intact.
Last reviewed 2026-05-12.