Tooling, Fixtures, Dies & Mold Economics worked example

Die Changeover Loss at 12% setup, purge, and first-piece allowance: a worked example in tooling, fixtures, dies & mold economics

This scenario runs the die changeover loss calculation on the strong side: 12% setup, purge, and first-piece allowance, with every other input held at its documented default. Use it when die changeover loss in tooling, fixtures, dies and mold economics is being added to next week's schedule and you need an honest hours estimate.

The inputs for this scenario

  • Dies to change over this shift: 120 units (unchanged)
  • Changeover completion rate per crew: 12 units / min (unchanged)
  • Setup, purge, and first-piece allowance: 12 % (raised for this scenario; the documented default is 10)

Working through the calculation

  • Applying the documented formula (Base die changeover loss time = die changeover loss workload รท die changeover loss completion rate) to the inputs above produces each figure below.
  • At this operating point the engine returns 11.2 hr for required die changeover loss time, the number this scenario is built around.
  • At this operating point the engine returns 10 hr for base die changeover loss time.
  • At this operating point the engine returns 12 % for die changeover loss allowance applied.
  • At this operating point the engine returns 12 pieces / min for die changeover loss completion rate.

How this compares with the baseline

  • Against the tool's baseline example, where setup, purge, and first-piece allowance sits at 10% and the headline result is 11 hr, this scenario comes in 1.82% above the baseline at 11.2 hr.
  • Use it when planning a changeover-heavy shift, justifying a SMED project, or reconciling why press availability is lower than the theoretical run time suggests. 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

  • Required die changeover loss time: 11.2 hr (headline result)
  • Base die changeover loss time: 10 hr
  • Die changeover loss allowance applied: 12 %
  • Die changeover loss completion rate: 12 pieces / min

Run it with your numbers

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

Last reviewed 2026-05-12.