Which setup tasks count as a loss?

Include tasks that stop the press, plus restart through the next accepted part. Preparation completed while it runs does not consume this stopped-time allowance.

Should I use ideal or actual production rate?

Use the observed accepted part rate during normal running. An ideal gross rate can overstate the good-part capacity displaced by a stop.

Why can remaining production time be negative?

The planned changes require more minutes than the entered window. Reschedule changes or increase available time before relying on the production plan.

Is lost capacity the same as lost sales?

No. Extra production later may recover it. A financial loss estimate also needs demand, recoverability and contribution margin.

Tooling, Fixtures, Dies & Mold Economics calculator

Die Changeover Loss Calculator

Estimate press time and good-part capacity consumed by die changes. Use measured exchange and restart times, the normal accepted production rate and the scheduled shift window.

What this calculator does

Quantify the good-part capacity displaced by die exchange and restart time within one press shift.

Formula used

Exchange minutes = die changes × internal exchange time
Restart minutes = die changes × restart and first-piece time
Stopped hours = (exchange minutes + restart minutes) ÷ 60
Lost good-part capacity = stopped minutes × normal good-part rate
Changeover share = 100 × stopped minutes ÷ scheduled window; remaining window = scheduled window − stopped minutes

Inputs explained

Die Changes in Shift: Whole sequential die exchanges scheduled on this press.
Internal Exchange Time: Measured press-stop time for removal, installation and setting.
Restart and First-Piece Time: Stopped time after exchange until the next accepted part.
Normal Good-Part Rate: Observed accepted production rate when the press is running.
Scheduled Production Window: Shift minutes available before subtracting these changeovers.

How to use the result

Best suited to press shift changeover Plan, internal setup reduction study.
An overbooked plan reports theoretical displaced capacity beyond the available window. Lost capacity can be recovered later and is not automatically lost revenue.

Current U.S. benchmarks

The producer price index for plastic resins and materials stands at 280.569 (BLS, Aug 2026), up 6.6% from a year earlier. Quotes priced off last quarter's material cost miss this move.
The U.S. has 14,378 furniture and related products establishments employing about 355,594 workers (Census County Business Patterns, 2023).

Common questions

Which setup tasks count as a loss? Include tasks that stop the press, plus restart through the next accepted part. Preparation completed while it runs does not consume this stopped-time allowance.
Should I use ideal or actual production rate? Use the observed accepted part rate during normal running. An ideal gross rate can overstate the good-part capacity displaced by a stop.
Why can remaining production time be negative? The planned changes require more minutes than the entered window. Reschedule changes or increase available time before relying on the production plan.
Is lost capacity the same as lost sales? No. Extra production later may recover it. A financial loss estimate also needs demand, recoverability and contribution margin.

Last reviewed 2026-10-06.