Metals, Steel, Aluminum & Coil Processing worked example

Coil Changeover Loss at 11% threading and setup allowance: a worked example

Suppose threading and setup allowance falls to 11%. This page works the full calculation at that level so you can see exactly which result moves and by how much. Estimate the run time lost to coil changeovers from the number of changeovers, how many the crew completes per hour, and a threading and setup allowance.

The inputs for this scenario

  • Coil changeovers in the run: 24 changeovers (held at the documented default)
  • Changeovers completed per hour: 6 changeovers / hr (held at the documented default)
  • Threading and setup allowance: 11 % (the input this scenario stresses; the baseline uses 15)

Working through the calculation

  • The calculation starts from the formula this tool documents: Base changeover time = coil changeovers in the run รท changeovers completed per hour.
  • Total changeover time works out to 4.44 hr at these inputs, and this is the headline figure for the scenario.
  • Base changeover time works out to 4 hr at these inputs.
  • Threading and setup allowance works out to 11 % at these inputs.
  • Changeovers completed per hour works out to 6 pieces / min at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where threading and setup allowance sits at 15% and the headline result is 4.6 hr, this scenario comes in 3.48% below the baseline at 4.44 hr.
  • It computes total changeover time as the number of coil changeovers divided by the changeover rate per hour, scaled up by a threading and setup allowance factor. When the numbers land here, the stressed input is the lever to work; the walkthrough above shows exactly how much each output recovers as it climbs back toward the baseline.

Results at a glance

  • Total changeover time: 4.44 hr (headline result)
  • Base changeover time: 4 hr
  • Threading and setup allowance: 11 %
  • Changeovers completed per hour: 6 pieces / min

Run it with your numbers

  • To rerun this with your own numbers, open the live Coil Changeover Loss calculator, set threading and setup allowance to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.