How do I weight the average cycle time?

Multiply each model's cycle time by its share of planned units and add the products. A 60/40 mix of 2.0 and 3.0 minute models gives 2.4 minutes. Use the planned mix for the shift, not last month's actuals.

Why count changeover time per shift?

Every changeover minute is a minute not making parts, and a mixed-model line pays that cost repeatedly. Sum the planned changeovers for the shift, then subtract them before dividing by the cycle.

Does this match what the line actually ships?

Only if the line runs at the weighted cycle with no other stoppages. Breaks, breakdowns and quality losses sit outside this figure, so use it for mix planning and then check actual good output.

What if demand is above capacity?

Recover the shortfall from the changeover block first, because that is usually the cheapest capacity to win back. If demand still exceeds capacity, add a shift or move work to another line.

Lean Manufacturing & Operations calculator

Mixed-Model Line Capacity Calculator

Work out how many units a line making several models can finish in a shift once changeovers take their time. Enter the net available minutes, the weighted-average cycle, changeover minutes and demand.

What this calculator does

Shift capacity for a mixed-model line after changeovers, with the gap against demand.

Formula used

Run time after changeovers = net available time − changeover time
Mixed-model capacity = run time after changeovers ÷ weighted-average cycle time
Capacity with zero changeover = net available time ÷ weighted-average cycle time
Units lost to changeovers = changeover time ÷ weighted-average cycle time
Capacity gap versus demand = mixed-model capacity − demand

Inputs explained

Net Available Time per Shift: Planned run minutes in the shift after breaks and meetings.
Weighted-Average Cycle Time: Cycle time averaged across the planned model mix.
Changeover Time per Shift: Total planned changeover minutes for the shift.
Demand per Shift: Units the shift schedule needs across all models.

How to use the result

Best suited to planning a four-model shift, weighing batch size against changeover, checking a high-changeover mix.
A mix change moves the average cycle, so recompute when demand proportions shift. Changeovers that overrun come straight out of capacity; this is the plan, not the result.

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

How do I weight the average cycle time? Multiply each model's cycle time by its share of planned units and add the products. A 60/40 mix of 2.0 and 3.0 minute models gives 2.4 minutes. Use the planned mix for the shift, not last month's actuals.
Why count changeover time per shift? Every changeover minute is a minute not making parts, and a mixed-model line pays that cost repeatedly. Sum the planned changeovers for the shift, then subtract them before dividing by the cycle.
Does this match what the line actually ships? Only if the line runs at the weighted cycle with no other stoppages. Breaks, breakdowns and quality losses sit outside this figure, so use it for mix planning and then check actual good output.
What if demand is above capacity? Recover the shortfall from the changeover block first, because that is usually the cheapest capacity to win back. If demand still exceeds capacity, add a shift or move work to another line.

Last reviewed 2026-10-01.