Injection Molding worked example

Mold Changeover Cost with changeover time of 6.25 hrs: a worked example in injection molding

This scenario runs the mold changeover cost calculation on the strong side: changeover time of 6.25 hrs, with every other input held at its documented default. Use this to quantify changeover costs when deciding between longer runs vs. more frequent changes, justifying quick-change tooling, or building SMED improvement business cases.

The inputs for this scenario

  • Changeover time (mold swap duration): 6.25 hrs (raised for this scenario; the documented default is 2.5)
  • Press hourly rate (with overhead): 125 $/hr (unchanged)
  • Setup labor rate (crew cost): 70 $/hr (unchanged)

Working through the calculation

  • Applying the documented formula (Changeover cost = Changeover time x (Press rate + Labor rate)) to the inputs above produces each figure below.
  • At this operating point the engine returns 54,688 $ for result, the number this scenario is built around.
  • At this operating point the engine returns 54,688 value for combined hourly rate (press + labor).
  • At this operating point the engine returns 1 x for multiplier.
  • At this operating point the engine returns 781 value for factor a x b.

How this compares with the baseline

  • Against the tool's baseline example, where changeover time sits at 2.5 hrs and the headline result is 21,875 $, this scenario comes in 150% above the baseline at 54,688 $.
  • Use it when deciding between longer runs and more frequent changes, building a SMED business case, or comparing scheduling options that batch jobs differently. Treat this as a target state: the delta against the baseline quantifies what the improvement is worth before you commit to chasing it.

Results at a glance

  • Result: 54,688 $ (headline result)
  • Combined hourly rate (press + labor): 54,688 value
  • Multiplier: 1 x
  • Factor A x B: 781 value

Run it with your numbers

  • Every input above is editable in the live Mold Changeover Cost calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.