Lean Manufacturing & Operations worked example

Changeover Frequency Impact at 99% target machine utilization: a worked example

Push target machine utilization up to 99% and the picture changes. This example computes every intermediate figure at that operating point. Use this calculator to quantify how much productive time is lost to changeovers. This helps justify SMED projects and determine optimal batch sizes.

The inputs for this scenario

  • Total changeover time per shift: 60 min (unchanged)
  • Total available production time: 450 min (unchanged)
  • Target machine utilization: 99 % (raised for this scenario; the documented default is 90)

Working through the calculation

  • Applying the documented formula (Changeover % = (Total Changeover Time / Available Time) x 100) to the inputs above produces each figure below.
  • At this operating point the engine returns 13.33 % for changeover time as % of available time, the number this scenario is built around.
  • At this operating point the engine returns 85.67 points for gap to utilization target.
  • At this operating point the engine returns 60 count for total changeover time.
  • At this operating point the engine returns 450 count for available production time.

How this compares with the baseline

  • Against the tool's baseline example, where target machine utilization sits at 90% and the headline result is 13.33 %, this scenario lands almost exactly on the baseline at 13.33 %.
  • It expresses total changeover time as a percentage of available production time and shows the gap to your utilization target. 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

  • Changeover time as % of available time: 13.33 % (headline result)
  • Gap to utilization target: 85.67 points
  • Total changeover time: 60 count
  • Available production time: 450 count

Run it with your numbers

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

Last reviewed 2026-05-12.