WonksAnonymous
Measuring the Cost of Unplanned Production Downtime
Three ways to value an hour of unplanned downtime (lost revenue, lost contribution, recovery cost), when each applies, and a worked 90-minute stop.
Production Economics
Unit costs, effective output, labor, bottlenecks, downtime, scrap and changeovers: what actually decides the cost of each good unit that leaves the line.
Small Batches and Frequent Changeovers: The Hidden Cost of Packaging
A model linking batch size, changeover time and run time to good packs and cost per good pack, with a worked shift example and a simple changeover log.
Rollstock Versus Premade Pouches: Comparing the Total Packaging Cost
How to put rollstock and premade pouches on one cost basis: material, waste, labor, equipment and order structure, with two worked scenarios and a break-even formula.
Cost per Good Pack: A More Useful Measure Than Nameplate Speed
How to define cost per good pack, avoid counting scrap twice, and keep equipment investment as a separate, labeled line, with a one-month worked example.
Why Faster Machines Do Not Always Increase Line Output
How bottlenecks, availability and good-unit output decide what a packaging line delivers, with a worked four-stage example and a pre-purchase measurement list.