Tooling, Fixtures, Dies & Mold Economics worked example

Die Changeover Loss at 7.2% setup, purge, and first-piece allowance: a worked example in tooling, fixtures, dies & mold economics

Suppose setup, purge, and first-piece allowance falls to 7.2%. This page works the full calculation at that level so you can see exactly which result moves and by how much. Estimate die changeover loss for tooling, fixtures, dies and mold economics using production-ready inputs so teams can plan labor hours, schedule the work, or check whether the job fits the available shift time.

The inputs for this scenario

Dies to change over this shift: 120 units (held at the documented default)
Changeover completion rate per crew: 12 units / min (held at the documented default)
Setup, purge, and first-piece allowance: 7.2 % (the input this scenario stresses; the baseline uses 10)

Working through the calculation

The calculation starts from the formula this tool documents: Base die changeover loss time = die changeover loss workload ÷ die changeover loss completion rate.
Required die changeover loss time works out to 10.72 hr at these inputs, and this is the headline figure for the scenario.
Base die changeover loss time works out to 10 hr at these inputs.
Die changeover loss allowance applied works out to 7.2 % at these inputs.
Die changeover loss completion rate works out to 12 pieces / min at these inputs.

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 2.55% below the baseline at 10.72 hr.
It converts a die-changeover workload and crew completion rate into base downtime, then inflates it by a setup and first-piece allowance to give required lost press time. When the numbers land here, the stressed input is the lever to work; the walkthrough above shows exactly how much each output recovers as it climbs back toward the baseline.

Results at a glance

Required die changeover loss time: 10.72 hr (headline result)
Base die changeover loss time: 10 hr
Die changeover loss allowance applied: 7.2 %
Die changeover loss completion rate: 12 pieces / min

Run it with your numbers

To rerun this with your own numbers, open the live Die Changeover Loss calculator, set setup, purge, and first-piece allowance to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.