Machine changeover batch tradeoff calculator

Calculate batch scenario table [size,batches,total minutes,setup share %,holding proxy currency] with your own figures.

Your numbers

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Use batch scenario table [size,batches,total minutes,setup share %,holding proxy currency] to compare changes to your inputs. The method and limits below explain the scope.

Examples

Examples

Try the starting example

Order size (units)
1000
Setup time per batch (min)
30
Cycle time per unit (min)
1
Candidate batch sizes (units)
100,250,500
Holding cost per unit per hour (USD/unit/hour)
0.01
Batch scenario table [size,batches,total minutes,setup share %,holding proxy currency] (USD)
[[100,10,1300,23.0769230769,10.8333333333],[250,4,1120,10.7142857143,23.3333333333],[500,2,1060,5.66037735849,44.1666666667]]

Try another scenario

Order size (units)
1000
Setup time per batch (min)
60
Cycle time per unit (min)
1
Candidate batch sizes (units)
100,250,500
Holding cost per unit per hour (USD/unit/hour)
0.01
Batch scenario table [size,batches,total minutes,setup share %,holding proxy currency] (USD)
[[100,10,1600,37.5,13.3333333333],[250,4,1240,19.3548387097,25.8333333333],[500,2,1120,10.7142857143,46.6666666667]]
Calculation method

Calculation method

Batch scenario table [size,batches,total minutes,setup share %,holding proxy currency] (USD)

For each q: batches=ceil(order/q), total=order*cycle+batches*setup, setupShare=100*batches*setup/total; holdingProxy=(q/2)*holdingRate*(total/60).

Symbols and units
a
Order size (units)
b
Setup time per batch (min)
c
Cycle time per unit (min)
d
Candidate batch sizes (units)
e
Holding cost per unit per hour (USD/unit/hour)

Use the units shown. A list keeps the order in which you enter its values. The symbol ^ means “raised to the power of”.

Assumptions & limits

Assumptions & limits

  • Sequential full-order production, partial last batch; holding proxy uses steady sawtooth average q/2 over production hours and is an approximation, not EOQ or total inventory-cost optimum. Supported limits: positive integer order and q<=order; setup>=0; cycle>0; holdingRate>=0; <=100 sizes.
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Further reading

Method reference ↗

Background reading; this does not imply endorsement or independent review of SumFizz.

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