Packaging Automation & End-of-Line Systems worked example

Packaging Changeover Time at 7.2% coordination and adjustment allowance: a worked example

This worked example runs the packaging changeover time numbers for a tougher week than the baseline: 7.2% coordination and adjustment allowance instead of the typical 10%. Estimate a packaging line changeover from the number of changeover steps, the rate steps are completed, and an allowance for coordination.

The inputs for this scenario

  • Changeover steps: 120 steps (held at the documented default)
  • Step completion rate: 12 steps / min (held at the documented default)
  • Coordination and adjustment allowance: 7.2 % (the input this scenario stresses; the baseline uses 10)

Working through the calculation

  • The calculation starts from the formula this tool documents: Base changeover time = changeover steps รท step completion rate.
  • Planned changeover time works out to 10.72 hr at these inputs, and this is the headline figure for the scenario.
  • Base changeover time works out to 10 hr at these inputs.
  • Coordination and adjustment allowance works out to 7.2 % at these inputs.
  • Step completion rate works out to 12 pieces / min at these inputs.

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 2.55% below the baseline at 10.72 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. 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

  • Planned changeover time: 10.72 hr (headline result)
  • Base changeover time: 10 hr
  • Coordination and adjustment allowance: 7.2 %
  • Step completion rate: 12 pieces / min

Run it with your numbers

  • To rerun this with your own numbers, open the live Packaging Changeover Time calculator, set coordination and adjustment allowance to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.