Lean Manufacturing & Operations worked example

Mixed-Model Line Capacity with net available production time per shift of 230 min: a worked example

This worked example runs the mixed-model line capacity numbers for a tougher week than the baseline: net available production time per shift of 230 min instead of the typical 450 min. Calculate effective mixed-model line capacity by accounting for product mix, weighted cycle time, and changeover impact across multiple product variants.

The inputs for this scenario

  • Net available production time per shift: 230 min (the input this scenario stresses; the baseline uses 450)
  • Weighted-average cycle time across the model mix: 2.5 min/unit (held at the documented default)
  • Total changeover time per shift: 45 min (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Mixed-Model Capacity = (Available Time - Changeover Time) / Weighted Cycle Time.
  • Effective output after changeover loss works out to 41.4 units / shift at these inputs, and this is the headline figure for the scenario.
  • Raw throughput works out to 92 units / shift at these inputs.
  • Changeover impact factor works out to 45 % at these inputs.
  • Available run time after changeovers works out to 2.5 hr at these inputs.

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 48.89% below the baseline at 41.4 units / shift.
  • Use it when planning daily output for a line that runs multiple products and incurs changeovers within the shift. A result at this level usually justifies acting on the stressed input before touching anything else, because every other figure in the table is downstream of it.

Results at a glance

  • Effective output after changeover loss: 41.4 units / shift (headline result)
  • Raw throughput: 92 units / shift
  • Changeover impact factor: 45 %
  • Available run time after changeovers: 2.5 hr

Run it with your numbers

  • To rerun this with your own numbers, open the live Mixed-Model Line Capacity calculator, set net available production time per shift to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.