Printing, Labels & Industrial Converting worked example

Flexo Makeready Loss at 99% flexo press uptime: a worked example

This scenario runs the flexo makeready loss calculation on the strong side: 99% flexo press uptime, with every other input held at its documented default. Use it when flexo makeready loss in printing, labels and industrial converting is being asked to take on more work and you need to know if there is room.

The inputs for this scenario

  • Impressions per makeready cycle: 4 units / cycle (unchanged)
  • Available makeready cycles per shift: 480 cycles (unchanged)
  • Flexo press uptime: 99 % (raised for this scenario; the documented default is 90)
  • First-pass yield after color registration: 97 % (unchanged)

Working through the calculation

  • Applying the documented formula (Gross flexo makeready loss capacity = flexo makeready loss output per cycle × available flexo makeready loss cycles) to the inputs above produces each figure below.
  • At this operating point the engine returns 1,844 units for good flexo makeready loss capacity, the number this scenario is built around.
  • At this operating point the engine returns 1,920 units for gross flexo makeready loss capacity.
  • At this operating point the engine returns 19.2 units for flexo makeready loss downtime loss.
  • At this operating point the engine returns 57.02 units for flexo makeready loss yield loss.

How this compares with the baseline

  • Against the tool's baseline example, where flexo press uptime sits at 90% and the headline result is 1,676 units, this scenario comes in 10% above the baseline at 1,844 units.
  • Use it when sizing achievable flexo output for a shift, quoting lead times, or diagnosing whether downtime or waste is your bigger loss. 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

  • Good flexo makeready loss capacity: 1,844 units (headline result)
  • Gross flexo makeready loss capacity: 1,920 units
  • Flexo makeready loss downtime loss: 19.2 units
  • Flexo makeready loss yield loss: 57.02 units

Run it with your numbers

  • Every input above is editable in the live Flexo Makeready Loss calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.