Heat Treatment, Furnaces & Thermal Processing worked example

Thermal Recipe Changeover at 61% setup window uptime: a worked example

Suppose setup window uptime falls to 61%. This page works the full calculation at that level so you can see exactly which result moves and by how much. Estimate thermal recipe changeover capacity from changeovers per cycle, available setup cycles, uptime, and first-pass setup yield.

The inputs for this scenario

  • Recipe changeovers per setup cycle: 1 changeovers / cycle (held at the documented default)
  • Available setup cycles per shift: 6 cycles / shift (held at the documented default)
  • Setup window uptime: 61 % (the input this scenario stresses; the baseline uses 85)
  • First-pass recipe setup yield: 95 % (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Gross recipe changeover capacity = changeovers per setup cycle × available setup cycles.
  • Qualified recipe changeover capacity works out to 3.48 qualified changeovers / shift at these inputs, and this is the headline figure for the scenario.
  • Gross changeover capacity works out to 6 qualified changeovers / shift at these inputs.
  • Setup downtime loss works out to 2.34 qualified changeovers / shift at these inputs.
  • Recipe setup yield loss works out to 0.18 qualified changeovers / shift at these inputs.

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 28.24% below the baseline at 3.48 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. When the numbers land here, the stressed input is the lever to work; the walkthrough above shows exactly how much each output recovers as it climbs back toward the baseline.

Results at a glance

  • Qualified recipe changeover capacity: 3.48 qualified changeovers / shift (headline result)
  • Gross changeover capacity: 6 qualified changeovers / shift
  • Setup downtime loss: 2.34 qualified changeovers / shift
  • Recipe setup yield loss: 0.18 qualified changeovers / shift

Run it with your numbers

  • To rerun this with your own numbers, open the live Thermal Recipe Changeover calculator, set setup window uptime to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.