Printing, Labels & Industrial Converting worked example

Job Gang-Run Savings at 59% gang capture efficiency: a worked example

This worked example runs the job gang-run savings numbers for a tougher week than the baseline: 59% gang capture efficiency instead of the typical 82%. Estimate net savings from combining multiple jobs on one sheet after layout efficiency and planning effort.

The inputs for this scenario

  • Jobs ganged onto one sheet: 8 jobs (held at the documented default)
  • Makeready and setup cost avoided per job: 95 $ / job (held at the documented default)
  • Gang capture efficiency: 59 % (the input this scenario stresses; the baseline uses 82)
  • Imposition and planning cost (enter negative): -140 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Gang-run savings = jobs ganged × per-job setup avoided × gang efficiency + imposition and planning cost.
  • Total job gang-run savings cost works out to 448 $ at these inputs, and this is the headline figure for the scenario.
  • Job gang-run savings cost per unit works out to 56.05 $ / piece at these inputs.
  • Variable job gang-run savings cost works out to 448 $ at these inputs.
  • Fixed job gang-run savings adder works out to 0 $ at these inputs.

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 28.05% below the baseline at 448 $.
  • Use it when deciding whether to batch several small jobs and when quoting a gang run to a customer. 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

  • Total job gang-run savings cost: 448 $ (headline result)
  • Job gang-run savings cost per unit: 56.05 $ / piece
  • Variable job gang-run savings cost: 448 $
  • Fixed job gang-run savings adder: 0 $

Run it with your numbers

  • To rerun this with your own numbers, open the live Job Gang-Run Savings calculator, set gang capture efficiency to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.