Robotics & Automation worked example

Robot Changeover Cost with parts in the next run of 2,000 parts: a worked example

This scenario runs the robot changeover cost calculation on the strong side: parts in the next run of 2,000 parts, with every other input held at its documented default. Use it when justifying SMED projects or batch size changes on a robotic cell so the changeover cost stack is on one page with cost per part.

The inputs for this scenario

  • Parts in the next run: 2,000 parts (raised for this scenario; the documented default is 800)
  • Lost throughput cost per part during changeover: 3.5 $ / part (unchanged)
  • Fixture and EOAT swap cost: 120 $ (unchanged)
  • Labor and overhead for changeover: 180 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Total robot changeover cost = parts in the next run x lost throughput cost per part during changeover + fixture and EOAT swap cost + labor and overhead for changeover) to the inputs above produces each figure below.
  • At this operating point the engine returns 7,300 $ for total robot changeover cost, the number this scenario is built around.
  • At this operating point the engine returns 3.65 $ / piece for cost per part.
  • At this operating point the engine returns 7,000 $ for lost throughput cost per part during changeover.
  • At this operating point the engine returns 300 $ for fixture, eoat, labor and overhead adders.

How this compares with the baseline

  • Against the tool's baseline example, where parts in the next run sits at 800 parts and the headline result is 3,100 $, this scenario comes in 135% above the baseline at 7,300 $.
  • Use it when setting economic run quantities, comparing changeover-reduction investments, or loading changeover into a quoted part price. 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

  • Total robot changeover cost: 7,300 $ (headline result)
  • Cost per part: 3.65 $ / piece
  • Lost throughput cost per part during changeover: 7,000 $
  • Fixture, EOAT, labor and overhead adders: 300 $

Run it with your numbers

  • Every input above is editable in the live Robot Changeover Cost calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.