Lean Manufacturing & Operations worked example
Mixed-Model Line Capacity with net available production time per shift of 1,100 min: a worked example
Push net available production time per shift up to 1,100 min and the picture changes. This example computes every intermediate figure at that operating point. Use this calculator when your line runs multiple product types to determine realistic total output capacity, weighted by the product mix and including changeover losses.
The inputs for this scenario
- Net available production time per shift: 1,100 min (raised for this scenario; the documented default is 450)
- Weighted-average cycle time across the model mix: 2.5 min/unit (unchanged)
- Total changeover time per shift: 45 min (unchanged)
Working through the calculation
- Applying the documented formula (Mixed-Model Capacity = (Available Time - Changeover Time) / Weighted Cycle Time) to the inputs above produces each figure below.
- At this operating point the engine returns 198 units / shift for effective output after changeover loss, the number this scenario is built around.
- At this operating point the engine returns 440 units / shift for raw throughput.
- At this operating point the engine returns 45 % for changeover impact factor.
- At this operating point the engine returns 2.5 hr for available run time after changeovers.
How this compares with the baseline
- Against the tool's baseline example, where net available production time per shift sits at 450 min and the headline result is 81 units / shift, this scenario comes in 144% above the baseline at 198 units / shift.
- It computes shift output as net available time minus total changeover time, divided by the weighted-average cycle time across the model mix. 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
- Effective output after changeover loss: 198 units / shift (headline result)
- Raw throughput: 440 units / shift
- Changeover impact factor: 45 %
- Available run time after changeovers: 2.5 hr
Run it with your numbers
- Every input above is editable in the live Mixed-Model Line Capacity calculator, which recalculates instantly and can be shared with the inputs intact.
Last reviewed 2026-05-12.