Wire Harness, Cable & Electromechanical Assembly worked example

Kitting Workload at 12% setup, handling & delay allowance: a worked example

What does the result look like when setup, handling & delay allowance reaches 12%? The full calculation is worked below with real intermediate numbers. Use it when kitting workload in wire harness, cable and electromechanical assembly is changing rate or allowance and you want to see the impact.

The inputs for this scenario

  • Kits to Assemble: 120 units (unchanged)
  • Kitting Pick Rate: 12 units / min (unchanged)
  • Setup, Handling & Delay Allowance: 12 % (raised for this scenario; the documented default is 10)

Working through the calculation

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

How this compares with the baseline

  • Against the tool's baseline example, where setup, handling & delay allowance sits at 10% and the headline result is 11 hr, this scenario comes in 1.82% above the baseline at 11.2 hr.
  • A figure at this level is achievable when setup, handling & delay allowance is genuinely sustained, not just peaked for a shift. A single average pick rate assumes uniform kit complexity; a run mixing simple and part-dense kits will deviate from the estimate.

Results at a glance

  • Required kitting workload time: 11.2 hr (headline result)
  • Base kitting workload time: 10 hr
  • Kitting workload allowance applied: 12 %
  • Kitting workload completion rate: 12 pieces / min

Run it with your numbers

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

Last reviewed 2026-05-12.