Free tool
Capacity Reality Check
Rated speed on the nameplate is not what a line makes in a week. Enter your lines and see what they can actually run after changeovers and real efficiency, and what a frozen schedule window would give back.
The three lines below are example numbers for a mid-size food plant. Change them to yours. Everything runs in your browser and nothing is sent anywhere.
Weekly demand
12,950
Realistic capacity
12,793
vs 19,200 rated (67%)
Gap
157 short
Tightest line
Filling line 1
109% loaded
+854 units a week come back if the schedule is frozen and the unplanned changeovers stop. That is 7% more output from the same lines, with no new equipment and no extra shifts.
525 units short (about 6.1 more run hours a week)
Changeovers take 12 of 80 scheduled hours. Realistic output is 61% of the rated figure.
242 units of room a week
Changeovers take 7 of 80 scheduled hours. Realistic output is 71% of the rated figure.
126 units of room a week
Changeovers take 3 of 40 scheduled hours. Realistic output is 74% of the rated figure.
What this is worth to you
$111,291
a year, plus a one-time cash release
Estimates from the numbers on this page. Rough figures are fine.
How the numbers work
- Scheduled hours = hours per shift × shifts per day × days per week.
- Changeover hours = (planned + unplanned changeovers) × hours per changeover.
- Run hours = scheduled hours minus changeover hours, never below zero.
- Rated output = rated units per hour × scheduled hours.
- Realistic output = rated units per hour × run hours × running efficiency.
- Frozen-window output = the same, counting only the planned changeovers.
- Loaded % = weekly demand ÷ realistic output.
On packaging lines, 65 to 80% running efficiency is common.
Want this on your real orders instead of estimates? Send a few Excel files, your open orders and line hours, with customer names blanked if you like, and we will show you the result in days.
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