Printing, Labels & Industrial Converting worked example

Job Gang-Run Savings at 94% gang capture efficiency: a worked example

What does the result look like when gang capture efficiency reaches 94%? The full calculation is worked below with real intermediate numbers. Use it when deciding whether ganging several small label or print jobs onto a shared sheet pays off versus running them separately.

The inputs for this scenario

  • Jobs ganged onto one sheet: 8 jobs (unchanged)
  • Makeready and setup cost avoided per job: 95 $ / job (unchanged)
  • Gang capture efficiency: 94 % (raised for this scenario; the documented default is 82)
  • Imposition and planning cost (enter negative): -140 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Gang-run savings = jobs ganged × per-job setup avoided × gang efficiency + imposition and planning cost) to the inputs above produces each figure below.
  • At this operating point the engine returns 714 $ for total job gang-run savings cost, the number this scenario is built around.
  • At this operating point the engine returns 89.3 $ / piece for job gang-run savings cost per unit.
  • At this operating point the engine returns 714 $ for variable job gang-run savings cost.
  • At this operating point the engine returns 0 $ for fixed job gang-run savings adder.

How this compares with the baseline

  • Against the tool's baseline example, where gang capture efficiency sits at 82% and the headline result is 623 $, this scenario comes in 14.63% above the baseline at 714 $.
  • A figure at this level is achievable when gang capture efficiency is genuinely sustained, not just peaked for a shift. It assumes uniform per-job setup savings; jobs with very different stocks, coatings or colors won't all gang cleanly and can erode the capture rate.

Results at a glance

  • Total job gang-run savings cost: 714 $ (headline result)
  • Job gang-run savings cost per unit: 89.3 $ / piece
  • Variable job gang-run savings cost: 714 $
  • Fixed job gang-run savings adder: 0 $

Run it with your numbers

  • Every input above is editable in the live Job Gang-Run Savings calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.