KEVOS® WORKOS · Manufacturing
Setup Reduction Value
Is reducing setup time worth the investment?
Values the time released by shorter changeovers and the payback on the improvement.
Open the calculatorRuns in your browser. No account needed.
How this tool works
Inputs, units and where to find them
| Input | Unit | Typical source |
|---|---|---|
| Current setup time | min | Measured current changeover time |
| Target setup time | min | Trialled or proven target changeover time |
| Changeovers / year | changes | Changeovers per year from production records |
| Combined hourly cost | $/hr | Hourly cost of the stopped machine and crew |
| Improvement investment | $ | Cost of tooling, fixtures and training for the faster set-up |
Method and formulas
- Hours released = (current − target) × changeovers ÷ 60
- Annual value = hours released × hourly cost
- Payback = investment ÷ annual value
Limitations
- Value is real only if the time is used
Typical uses
- SMED projects
- Justifying quick-change tooling
Who it is for
- Production engineers
- Lean practitioners
What you get
- Hours released and annual value
- Payback
Interpreting the result
- Faster set-ups also allow smaller batches and less inventory
References
- Shingo S., A Revolution in Manufacturing: The SMED System (Productivity Press, 1985)
WORKOS tools are screening and decision-support utilities. Verify important financial, engineering, safety, legal or operational decisions using appropriate professional standards and your organisation’s approved data.
