Printing, Labels & Industrial Converting worked example

Flexo Makeready Loss at 65% flexo press uptime: a worked example

This worked example runs the flexo makeready loss numbers for a tougher week than the baseline: 65% flexo press uptime instead of the typical 90%. Estimate flexo makeready loss for printing, labels and industrial converting using production-ready inputs so teams can confirm whether capacity can cover demand before committing the schedule.

The inputs for this scenario

  • Impressions per makeready cycle: 4 units / cycle (held at the documented default)
  • Available makeready cycles per shift: 480 cycles (held at the documented default)
  • Flexo press uptime: 65 % (the input this scenario stresses; the baseline uses 90)
  • First-pass yield after color registration: 97 % (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Gross flexo makeready loss capacity = flexo makeready loss output per cycle × available flexo makeready loss cycles.
  • Good flexo makeready loss capacity works out to 1,211 units at these inputs, and this is the headline figure for the scenario.
  • Gross flexo makeready loss capacity works out to 1,920 units at these inputs.
  • Flexo makeready loss downtime loss works out to 672 units at these inputs.
  • Flexo makeready loss yield loss works out to 37.44 units at these inputs.

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 27.78% below the baseline at 1,211 units.
  • Use it when sizing achievable flexo output for a shift, quoting lead times, or diagnosing whether downtime or waste is your bigger loss. 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

  • Good flexo makeready loss capacity: 1,211 units (headline result)
  • Gross flexo makeready loss capacity: 1,920 units
  • Flexo makeready loss downtime loss: 672 units
  • Flexo makeready loss yield loss: 37.44 units

Run it with your numbers

  • To rerun this with your own numbers, open the live Flexo Makeready Loss calculator, set flexo press uptime to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.