Wood & Paper Manufacturing worked example

Roll Change Loss at 50% defective splice rate: a worked example

This worked example runs the roll change loss numbers for a tougher week than the baseline: 50% defective splice rate instead of the typical 70%. Estimates the scrap and downtime cost of parent roll changes on a paper or converting line.

The inputs for this scenario

  • Roll changes per production run: 12 changes (held at the documented default)
  • Cost per roll change: 140 $/change (held at the documented default)
  • Defective splice rate: 50 % (the input this scenario stresses; the baseline uses 70)
  • Crew standby charge per run: 260 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Roll change loss = roll changes x cost per change x defective splice% + crew standby charge.
  • Total roll change loss cost works out to 1,100 $ at these inputs, and this is the headline figure for the scenario.
  • Roll change loss cost per unit works out to 91.67 $ / piece at these inputs.
  • Variable roll change loss cost works out to 840 $ at these inputs.
  • Fixed roll change loss adder works out to 260 $ at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where defective splice rate sits at 70% and the headline result is 1,436 $, this scenario comes in 23.4% below the baseline at 1,100 $.
  • Use it when justifying automatic splicer investment, comparing roll suppliers, or costing the impact of splice-failure rates on a run. A result at this level usually justifies acting on the stressed input before touching anything else, because every other figure in the table is downstream of it.

Results at a glance

  • Total roll change loss cost: 1,100 $ (headline result)
  • Roll change loss cost per unit: 91.67 $ / piece
  • Variable roll change loss cost: 840 $
  • Fixed roll change loss adder: 260 $

Run it with your numbers

  • To rerun this with your own numbers, open the live Roll Change Loss calculator, set defective splice rate to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.