Line Loss Finder

Answer for one production line in a typical week. Rough numbers are fine. Your answers stay in your browser; nothing is uploaded.

1. Line name e.g. "Line 2 — biscuits"

2. Planned production hours per week Shift hours the line is meant to run, minus planned breaks 3. Weeks the line runs per yearDefault 48 4. Changeovers per weekProduct, SKU, format or pack-size changes 5. Average changeover time (minutes)Last good product to first good product 6. Unplanned downtime per week (hours)Breakdowns, waiting for materials, stops over ~2 min 7. Rated (ideal) speed — units per minuteNameplate or best sustained speed 8. Actual average speed when running — units per minuteOutput ÷ run time 9. Scrap + rework (% of units made) 10. Pack-weight giveaway (% over declared weight)Enter 0 if not relevant 11. Crew on the line (people) 12. Loaded labour cost per person-hour (NZD)Wage + on-costs 13. Material cost per unit (NZD)Ingredients + packaging 14. Contribution margin per unit (NZD)Price minus variable cost. Used only if the line is sold out

15. Could you sell more from this line if it made more? "Yes" values lost time at lost margin; "No" values it at labour cost only (more conservative)