Packaging Automation & End-of-Line Systems worked example

Packaging Changeover Time at 12% coordination and adjustment allowance: a worked example

This scenario runs the packaging changeover time calculation on the strong side: 12% coordination and adjustment allowance, with every other input held at its documented default. Use it when you are scheduling a format or product changeover and need a realistic time for the line.

The inputs for this scenario

  • Changeover steps: 120 steps (unchanged)
  • Step completion rate: 12 steps / min (unchanged)
  • Coordination and adjustment allowance: 12 % (raised for this scenario; the documented default is 10)

Working through the calculation

  • Applying the documented formula (Base changeover time = changeover steps รท step completion rate) to the inputs above produces each figure below.
  • At this operating point the engine returns 11.2 hr for planned changeover time, the number this scenario is built around.
  • At this operating point the engine returns 10 hr for base changeover time.
  • At this operating point the engine returns 12 % for coordination and adjustment allowance.
  • At this operating point the engine returns 12 pieces / min for step completion rate.

How this compares with the baseline

  • Against the tool's baseline example, where coordination and adjustment allowance sits at 10% and the headline result is 11 hr, this scenario comes in 1.82% above the baseline at 11.2 hr.
  • Use it when scheduling format or SKU switches, sizing the time block for a SMED study, or estimating availability loss from changeovers across a shift. Treat this as a target state: the delta against the baseline quantifies what the improvement is worth before you commit to chasing it.

Results at a glance

  • Planned changeover time: 11.2 hr (headline result)
  • Base changeover time: 10 hr
  • Coordination and adjustment allowance: 12 %
  • Step completion rate: 12 pieces / min

Run it with your numbers

  • Every input above is editable in the live Packaging Changeover Time calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.