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Calcimator

Changeover Time Calculator

Analyze setup and changeover time to identify SMED improvement opportunities and quantify savings.

Inputs

min
min
min
$

Results

Improved Changeover Time

20 min

Time Saved per Changeover25 min
Improvement55.6%
Annual Time Saved208.5 hrs
Annual Cost Savings$31,275.00
Weekly Changeover (Before)7.5 hrs
Weekly Changeover (After)3.3 hrs
How to Use This Calculator
  1. Enter the current changeover time in minutes from last good part to first good part.
  2. Break down changeover into internal (machine stopped) and external (can be done while running) elements.
  3. Input the time for each internal and external element.
  4. Review the quick-win opportunity: converting internal elements to external using SMED methodology.
  5. Target a reduction to under 10 minutes for most changeovers by eliminating and parallelizing steps.

How the result changes with Internal Time (Machine Stopped)

Internal Time (Machine Stopped)Improved Changeover Time
4848 min
168168 min
312312 min
432432 min

What each input means

Current Changeover Time
Total current changeover duration from last good part to first good part.
Internal Time (Machine Stopped)
Tasks that can only be done while the machine is stopped.
External Time (Machine Running)
Tasks that can be moved to while the machine is still running.
Changeovers per Week
Average number of product changeovers per week.
Machine Hourly Cost
Fully loaded cost per hour of machine downtime (machine + labor + overhead).

How this is calculated

Worked example, using the default values

  1. Identify Input Parameters
    4 parameters
    Current Changeover Time = 45, Internal Time (Machine Stopped) = 20, External Time (Machine Running) = 25, Changeovers per Week = 10 = 5 input(s) provided
  2. Calculate Improved Changeover Time
    Improved Changeover Time
    20 = 20
  3. Calculate Time Saved per Changeover
    Time Saved per Changeover
    25 = 25
  4. Calculate Improvement
    Improvement
    55.6 = 55.6%

Engine last updated . Checked against 2 independently-derived tests — how we verify calculators.

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