SMED · Setup Reduction
Changeover Savings Calculator
Every changeover is planned downtime that nobody counts as downtime. Enter how often and how long your lines change over, and see the hours a year it costs — and what halving it would be worth in capacity or cash.
Calculator
Tell us about your changeovers:
Per line. Include size, colour and product changes.
Last good piece to first good piece at rate.
What a faster setup could achieve — often half the current time on a first pass.
Contribution margin the line earns per running hour.
A first SMED pass — separating external from internal setup — typically cuts changeover time by 50% with no capital.
Changeovers are costing you every year
₹4.86 L
The figures behind it:
Total time saved per month
54 hrs
Annualized
₹58.3 L
Want to know more?
Enter your work email if you would like a Gemba consultant to review these figures with you.
One number usually points at another.
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