Manufacturing & Industry Calculators — United Kingdom
Line efficiency, quality yield and capacity. Standard operations arithmetic, in your own units and currency.
Equipment effectiveness
OEE Calculator
Overall equipment effectiveness from availability, performance and quality — and which of the three is costing you most.
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Takt Time Calculator
The pace demand requires, against the pace your line actually achieves.
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Machine Utilisation Calculator
How much of a machine's available time is productive — and what an extra hour is worth.
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Material Utilisation Calculator
How many parts a sheet or bar yields, the material actually used against the material bought, and what the offcuts cost — the arithmetic behind nesting.
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Changeover Time Calculator
How much capacity changeovers consume, what that costs, and how much a changeover reduction — SMED — gives back in production time and smaller economic batches.
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Downtime Cost Calculator
The full cost of an hour of downtime — lost output, idle labour, restart scrap and any penalties — and what that makes a reliability investment worth.
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Line Balancing Calculator
The minimum number of workstations an assembly line needs to hit a takt time, the balance efficiency of a given station count, and where the idle time sits.
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Labour Productivity Calculator
Output per labour hour and per person, the labour cost per unit that follows, and what a productivity improvement is worth in units, cost and headcount.
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Feeds and Speeds Calculator
Spindle speed from cutting speed and tool diameter, feed rate from chip load and flutes, the material removal rate that follows, the spindle power it needs and the time to cut a given length — the four numbers every CNC program starts with.
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Robot Cycle Time Calculator
The cycle time of a robot from the moves it makes — each a trapezoidal profile of acceleration, cruise and deceleration — plus the dwells for gripping and processing, and the parts per hour and per shift that follow.
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Machine Energy Per Part Calculator
The electricity a machine consumes per part — the cutting or forming energy plus its share of the idle power drawn while waiting — with the cost per part, per shift and the waste that idling represents.
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Quality & yield
Scrap Rate and Yield Calculator
Scrap rate, first-pass yield, and the rolled yield that multi-step processes actually deliver.
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First Pass Yield Calculator
First pass yield at each step and the rolled throughput yield across a whole process — the share of units that get through every step right first time, which is far lower than any single step suggests.
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Six Sigma DPMO Calculator
Defects per million opportunities from a sample, the sigma level it corresponds to, and what reaching the next sigma level would mean in defects avoided.
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Tolerance Stack-Up Calculator
How the tolerances of parts in a chain add up — the worst case, where every part is at its limit, and the statistical root-sum-square that assembly actually sees.
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MTBF and MTTR Calculator
Mean time between failures and mean time to repair from a period's failure records — with the availability they imply, the failure rate, the chance of surviving a mission time, and what halving repair time would do.
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Injury Rate Calculator
A workplace's injury rates from its records — the total recordable rate per 200,000 hours, the lost-time frequency per million hours, and the severity rate — so that sites of different sizes can be compared.
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Acceptance Sampling Calculator
For a single sampling plan — inspect n items, accept the lot if no more than c are defective — the probability of accepting a lot with a given defect rate, the average outgoing quality, and the inspection the plan really costs.
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Capacity & ordering
Economic Order Quantity Calculator
The order size that minimises total cost, balancing ordering against holding.
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Production Capacity Calculator
What a line can actually produce, against what it is nominally rated for.
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Cost Per Part Calculator
The cost to make one part — material, labour, machine time, tooling amortised over the run and overhead — and how the unit cost falls as the batch grows.
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Tooling Cost Amortisation Calculator
What a tool, die or mould costs per part — amortised over the volume it will actually make — and the volume at which buying it beats paying a supplier's tooling charge.
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Lead Time Calculator
Total lead time from order to delivery, built from its parts — processing, procurement, production, queueing and shipping — and how much of it is actually work.
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Inventory Days Calculator
How many days of demand the stock on hand covers, the capital it ties up, and what reducing it releases — the number a warehouse is judged on.
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Freight Cost Per Unit Calculator
A shipment's freight cost broken down to the pallet, the carton and the unit — allowing for pallets that are not full — with what a full load would cost per unit and how much the empty space is costing.
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Equipment Replacement Calculator
Whether to keep an ageing machine or replace it — the present value of running each over the horizon, with rising maintenance and downtime on the old one against the price, lower costs and productivity gain of the new — and the year the decision flips.
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About these calculators
These compute the standard operations-management measures from figures you supply. OEE in particular is defined consistently in the literature but applied inconsistently in practice — what counts as planned downtime is the usual source of disagreement, and it changes the number substantially.