Wire Harness, Cable & Electromechanical Assembly worked example

Kitting Workload at 7.2% setup, handling & delay allowance: a worked example

Suppose setup, handling & delay 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 kitting workload for wire harness, cable and electromechanical assembly 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

  • Kits to Assemble: 120 units (held at the documented default)
  • Kitting Pick Rate: 12 units / min (held at the documented default)
  • Setup, Handling & Delay 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 kitting workload time = kitting workload workload รท kitting workload completion rate.
  • Required kitting workload time works out to 10.72 hr at these inputs, and this is the headline figure for the scenario.
  • Base kitting workload time works out to 10 hr at these inputs.
  • Kitting workload allowance applied works out to 7.2 % at these inputs.
  • Kitting workload 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, handling & delay 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 kit quantity and a pick rate into base kitting hours, then inflates that by an allowance factor to give the realistic required 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 kitting workload time: 10.72 hr (headline result)
  • Base kitting workload time: 10 hr
  • Kitting workload allowance applied: 7.2 %
  • Kitting workload completion rate: 12 pieces / min

Run it with your numbers

  • To rerun this with your own numbers, open the live Kitting Workload calculator, set setup, handling & delay allowance to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.