Why is lead time days when the run takes a few hours?

Because the batch spends most of its time waiting, not running. At the defaults it runs 9.0 hours of a 34.0-hour lead time, so run share is 26%. Queue, setup and post-run hours make up the rest.

Where do I get queue time if I have no MES?

From router sign-offs: the gap between the previous operation's completion and setup start here, averaged over recent jobs. With no records, estimate it as the hours of work already waiting ahead of this job.

Does a smaller run quantity always shorten lead time?

It shortens this batch's run time, but every extra batch needs another setup. If the work center is near full load, those setups lengthen the queue for every job, which can cost more than the run time saved.

Is inspection value-added time?

No. Inspection finds defects but does not change the part, so it sits with wait and move time. Run share counts only run time, so it is the most of this lead time that can be value-added.

Planning calculator

Manufacturing Lead Time Calculator

Find how many working days a batch takes through one work center when you quote a date or size a run. You need queue, setup and post-run hours, the run quantity, cycle time and your working day.

What this calculator does

Working days one batch spends at a work center, built from queue, setup, run, inspection and move time.

Formula used

Run time (hr) = run quantity × cycle time ÷ 3,600 sec per hr
Lead time (hr) = queue + setup + run + inspection, wait and move
Lead time (days) = lead time (hr) ÷ working hours per day
Queue share = queue ÷ lead time (hr) × 100; run share = run ÷ lead time (hr) × 100

Inputs explained

Queue Time: Working hours the batch waits here before setup starts.
Setup Time: Changeover hours, last good part to first good part.
Run Quantity: Units on the work order.
Cycle Time: Demonstrated seconds per unit at this work center.
Inspection, Wait and Move Time: Working hours after the run: inspection, waiting for pickup, transit.
Working Hours per Day: Scheduled hours per day on this work center.

How to use the result

Best suited to quoting a ship date for one batch, comparing one long run with split batches, finding the biggest wait in a routing step.
Covers one operation; add each routing step, or use value stream lead time for the whole order. Queue time is an input, not a forecast: it changes with the load on the work center.

Current U.S. benchmarks

U.S. manufacturing runs at 75.7% of capacity (Federal Reserve, Aug 2026). New factory orders are up 8.5% year over year (Census).

Common questions

Why is lead time days when the run takes a few hours? Because the batch spends most of its time waiting, not running. At the defaults it runs 9.0 hours of a 34.0-hour lead time, so run share is 26%. Queue, setup and post-run hours make up the rest.
Where do I get queue time if I have no MES? From router sign-offs: the gap between the previous operation's completion and setup start here, averaged over recent jobs. With no records, estimate it as the hours of work already waiting ahead of this job.
Does a smaller run quantity always shorten lead time? It shortens this batch's run time, but every extra batch needs another setup. If the work center is near full load, those setups lengthen the queue for every job, which can cost more than the run time saved.
Is inspection value-added time? No. Inspection finds defects but does not change the part, so it sits with wait and move time. Run share counts only run time, so it is the most of this lead time that can be value-added.

Related guides

Cutting Manufacturing Lead Time Systematically

Last reviewed 2026-10-01.