Sheet Metal Stamping & Press Lines worked example

Die Changeover Cost at 58% cost capture factor: a worked example in sheet metal stamping & press lines

This worked example runs the die changeover cost numbers for a tougher week than the baseline: 58% cost capture factor instead of the typical 80%. A die changeover ties up a press, a setter, and often a forklift while the line makes zero parts, so its true cost blends variable machine time with a fixed setup charge.

The inputs for this scenario

  • Parts run before the changeover: 100 units (held at the documented default)
  • Machine cost rate: 45 $ / unit (held at the documented default)
  • Cost capture factor: 58 % (the input this scenario stresses; the baseline uses 80)
  • Fixed setup cost: 250 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Die Changeover Cost cost = quantity × rate × capture factor + fixed cost.
  • Weighted cost works out to 2,860 $ at these inputs, and this is the headline figure for the scenario.
  • Per piece value works out to 28.6 $ / piece at these inputs.
  • Captured value works out to 2,610 $ at these inputs.
  • Fixed adjustment works out to 250 $ at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where cost capture factor sits at 80% and the headline result is 3,850 $, this scenario comes in 25.71% below the baseline at 2,860 $.
  • Use it when sizing production batches, building a quote, or ranking changeovers for a SMED reduction effort. 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

  • Weighted cost: 2,860 $ (headline result)
  • Per piece value: 28.6 $ / piece
  • Captured value: 2,610 $
  • Fixed adjustment: 250 $

Run it with your numbers

  • To rerun this with your own numbers, open the live Die Changeover Cost calculator, set cost capture factor to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.