Robotics & Automation worked example

Robot Changeover Cost with parts in the next run of 400 parts: a worked example

This worked example runs the robot changeover cost numbers for a tougher week than the baseline: parts in the next run of 400 parts instead of the typical 800 parts. Estimate dollar cost of a robot cell changeover including lost throughput, labor, fixture/EOAT swap, and support overhead, with cost per part for the run.

The inputs for this scenario

  • Parts in the next run: 400 parts (the input this scenario stresses; the baseline uses 800)
  • Lost throughput cost per part during changeover: 3.5 $ / part (held at the documented default)
  • Fixture and EOAT swap cost: 120 $ (held at the documented default)
  • Labor and overhead for changeover: 180 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: 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.
  • Total robot changeover cost works out to 1,700 $ at these inputs, and this is the headline figure for the scenario.
  • Cost per part works out to 4.25 $ / piece at these inputs.
  • Lost throughput cost per part during changeover works out to 1,400 $ at these inputs.
  • Fixture, EOAT, labor and overhead adders works out to 300 $ at these inputs.

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 45.16% below the baseline at 1,700 $.
  • Use it when setting economic run quantities, comparing changeover-reduction investments, or loading changeover into a quoted part price. 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 robot changeover cost: 1,700 $ (headline result)
  • Cost per part: 4.25 $ / piece
  • Lost throughput cost per part during changeover: 1,400 $
  • Fixture, EOAT, labor and overhead adders: 300 $

Run it with your numbers

  • To rerun this with your own numbers, open the live Robot Changeover Cost calculator, set parts in the next run to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.