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EPEI and batch size calculator
EPEI (every part every interval) is how often a machine that runs several part numbers makes each of them: if every part comes round at least once every two days, the EPEI is two days. A common way to calculate it starts from the time the machine has each day. Take away the production time the demand needs (daily demand × cycle time, added up over the parts) and what is left is the time for changeovers. EPEI = the changeover time for one cycle of all parts ÷ the time left per day, rounded up to an interval you can schedule. The batch size for each part is then its daily demand × EPEI, because each run has to cover the demand until that part comes round again. Page 1 of this template is the calculator sheet: the available time, one row per part with demand, cycle time and changeover, and the results now and with the shorter changeovers you expect after SMED. Page 2 has how to use it, the formulas, what to do when no time is left for changeovers and a worked example. The Excel version takes up to 20 parts, does the sums, rounds the EPEI up to a step you set, flags missing inputs and a machine with no time left, and charts the batch size of each part now and after SMED.
Free to use: print it, copy it and edit it for your team. Enter your name and work email once to download.
Fields for machine, parts, demand period, planner and date, a fifteen-row table of part numbers with daily demand, cycle time, changeover time, production time and batch size now and after SMED, a box for the available time per day and a results box from production time to EPEI and spare time, now and after SMED.Available timeProduction time per partTime left for changeoversEPEIBatch size per partAfter-SMED what-ifNo-time flagWorked example
When to use it
When to use an EPEI and batch size calculator
- When a machine or line shared by several part numbers runs batches set by habit or by the planning system, and nobody knows what its changeovers allow.
- Before a SMED project, to see how much each minute of changeover time is worth in batch size and stock.
- After a SMED project, to reset the batch sizes and the production cycle to the shorter changeovers.
- When demand or the part mix changes, or a part moves to another machine, to check the machine still has time for its changeovers.
How to fill it in
- 1
Work out the available time
Shifts × (minutes per shift − breaks and meetings) − other planned stops, in minutes a day on this machine.
- 2
List the parts
Every part number the machine runs, with its average daily demand, cycle time per piece and the changeover time into that part, from the last good piece of the part before to the first good piece of this one.
- 3
Find the time left for changeovers
Production time per part = daily demand × cycle time ÷ 60. Take the total away from the available time. If nothing is left, stop: the machine cannot make the demand even with no changeovers.
- 4
Work out the EPEI
Add up the changeover times for one cycle of all parts and divide by the time left per day. Round up to an interval you can schedule, such as a shift, a day or a week.
- 5
Size the batches
Batch size = daily demand × EPEI used. Round up to whole containers if the parts move in fixed packs.
- 6
Try the changeovers after SMED
Write the changeover times you expect after SMED and compare the EPEI and the batches. Start the SMED work where the minutes saved shrink the cycle most.
A filled-in example
Illustrative, not a benchmarkAn example: press 4 runs five brackets, BR-10 to BR-50 (illustrative numbers; the rounding step of 1 day is an example value, set your own).
The example press, before and after SMED
EPEI = changeover time for one cycle ÷ time left for changeovers a day
Time left: 880 available − 700 production = 180 minutes a day.
- Before =240 ÷ 180 = 1.33, rounded up= 2 days
- After SMED =105 ÷ 180 = 0.58, rounded up= 1 day
Changeover minutes for one cycle of all five parts
- Before
- 240
- After SMED
- 105
180 minutes a day are left for changeovers. Before: 240 minutes of changeovers a cycle, EPEI 1.33 days, rounded to 2. After: 105 minutes, EPEI 0.58, rounded to 1 day.
- Available time: 2 shifts × (480 − 30 minutes of breaks) − 20 minutes of other planned stops = 880 minutes a day.
- Daily demand 1,200, 800, 600, 300 and 150 pieces at cycle times of 12, 15, 10, 20 and 24 seconds: production time 240 + 200 + 100 + 100 + 60 = 700 minutes, 79.5% of the available time. 880 − 700 = 180 minutes a day are left for changeovers.
- Changeovers today take 45, 60, 30, 45 and 60 minutes: 240 minutes for one cycle. EPEI = 240 ÷ 180 = 1.33 days, rounded up to 2 days. Batches = demand × 2: 2,400, 1,600, 1,200, 600 and 300 pieces, with 120 minutes of changeovers a day and 60 minutes spare.
- After SMED the changeovers take 20, 25, 15, 20 and 25 minutes: 105 minutes a cycle. EPEI = 105 ÷ 180 = 0.58 days, rounded up to 1 day. Batches = 1,200, 800, 600, 300 and 150 pieces, with 75 minutes spare.
Cutting the changeovers from 240 to 105 minutes a cycle takes the EPEI from 2 days to 1, so every part runs every day and each batch halves: 6,100 pieces a cycle become 3,050. With a half-day step on two shifts, today's 1.33 days could also be rounded to 1.5 days, giving batches of 1,800, 1,200, 900, 450 and 225.
Common mistakes
Using the shift length as the available time
Breaks, meetings and planned stops are not production time. Leave them in and the time left for changeovers looks bigger than it is, and the EPEI comes out too short to keep.
Sizing batches when no time is left
If the production time alone is more than the available time, no batch size will work. Fix the capacity first: cycle time, downtime, more time or another machine.
Keeping the old batch sizes after SMED
Shorter changeovers only reduce stock when the batches and the production cycle are reset to them. Otherwise the saved minutes become idle time.
Trusting a single average
Changeover times that vary a lot, demand that swings by week and minimum batches such as a full coil or a full oven can all push the EPEI up. Check the result on the floor before you commit to it.
Download the template
Free to use: print it, copy it and edit it for your team. Enter your name and work email once to download.
Run this template in LeanSuite
In LeanSuite every changeover runs as a digital checklist that logs how long each step took, and Vision AI splits a filmed changeover into internal and external tasks and proposes a shorter sequence.
See it in a 45-minute demoIn the lean glossary
FAQ
EPEI and batch size calculator: common questions
EPEI stands for every part every interval (also every product every interval): how often a machine makes each of the part numbers it runs. If every part comes round at least once every two days, the EPEI is two days. A shorter EPEI means smaller batches and less stock, and it depends mainly on the changeover times and the number of parts on the machine.
Take the production time the demand needs (daily demand × cycle time, added up over the parts) away from the available time per day. What is left is the time for changeovers. EPEI = the changeover time for one cycle of all parts ÷ that time left. With 880 minutes available, 700 minutes of production and 240 minutes of changeovers a cycle: 240 ÷ 180 = 1.33 days, rounded up to 2 days.
Batch size = daily demand × EPEI used, because each run has to cover the demand until the part comes round again. A part needed 1,200 times a day with an EPEI of 2 days runs in batches of 2,400. Halve the EPEI and every batch halves.
Then the production time alone is more than the available time, and the machine cannot make the demand even with no changeovers. No batch size fixes that. Shorten the cycle times, cut downtime, add time or move a part to another machine, then work out the EPEI again. The Excel version flags this case.
This calculator sets how often each part runs on one machine and how big each batch is, from the time left for changeovers. The heijunka box planner then spreads the product mix through the day in pitch slots, the SMED changeover worksheet and SMED calculator shorten one changeover, and the kanban sizing calculator counts the cards for a pull loop.
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- Gage R&R study sheet10 parts, 2 or 3 appraisers, 2 or 3 trials: EV, AV, GRR, PV, %GRR and ndc by the average and range method.
- Root cause analysis templateOne report from problem statement to proof: containment, evidence, analysis, verified causes, actions and the effectiveness check.
- Safety pillar 90-day model area planThirteen weeks from the incident pyramid to safety standards on one model area, a KPI board, the day-90 gate and expansion waves.
- Quality control pillar 90-day model area planThirteen weeks from the QA matrix to the QM matrix on one model area, a KPI board, the day-90 gate and expansion waves.
- Autonomous maintenance 90-day model area planAM steps 0 to 3 on one model machine in 13 weeks, a KPI board, the day-90 gate and expansion waves for months 4 to 12.
- Professional maintenance (PM) 90-day model area planThirteen weeks from breakdown analysis to a running PM calendar on one model machine, a KPI board, the day-90 gate and expansion waves.
- Environment and energy pillar 90-day model area planThirteen weeks from waste and energy maps to area standards on one model area, a KPI board, the day-90 gate and expansion waves.
- Focused improvement 90-day model area planThirteen weeks from the loss Pareto to standardized fixes on one model line, a KPI board, the day-90 gate and expansion waves.
- People development pillar 90-day model area planThirteen weeks from the skills matrix to trained cover on critical tasks in one model area, a KPI board, the day-90 gate and expansion waves.
- Early equipment management 90-day model area planThirteen weeks from lessons on current machines to a tracked start-up on one model equipment project, a KPI board, the day-90 gate and expansion waves.
- Cost deployment pillar 90-day model area planThirteen weeks from the loss map to costed, ranked projects in one model area, a KPI board, the day-90 gate and expansion waves.
- Prioritization matrix templateScore up to 20 improvement ideas on weighted criteria, rank them, test the ranking with equal weights and place each one on an effort and benefit grid.
- Cost per unit worksheet (manufacturing cost per good unit)One product's cost per good unit by materials, labor, machine and overhead, the gap to target, and which cost lever is worth most a year.
- RCM worksheet (failure mode and task selection)Failure modes classed as hidden, safety, operational or non-operational, then a task chosen for each: condition-based, discard, failure-finding, redesign or run to failure.
- Error-proofing verification log (daily master-sample check)Each poka-yoke device proved every day or week with a known-bad sample, with missed checks counted and the hours and parts at risk worked out when one fails.
- Training matrix template with expiry datesPeople by required trainings with expiry dates, OK, due, expired and missing flags, compliance by person and area, cover per training and a renewal list.
- Defect catalogue template with boundary samplesEvery defect with a definition, a class and the reason for it, measured accept and reject limits by zone, boundary samples, a defect log with DPU and Pareto, and an inspector agreement check.
- I-MR chart template (individuals and moving range)Up to 100 single readings with moving ranges, limits from a baseline, five run-rule flags, both charts, a second phase and a reaction log.
- Kaizen event preparation checklistEverything that has to be ready before a kaizen event and done after it: 44 items with owners and due dates from 6 weeks before day 1 to 30 days after, five go or no-go gates and a day-by-day agenda.
- Attribute control chart template (p, np, c and u charts)p, np, c and u charts in one workbook: a chart selector, a sample size check, limits for each subgroup, signal flags and four worked examples.
- Critical spare parts list and stocking levelsAssets ranked by consequence, each part classed and given a stocking policy, and min and max worked out from usage and lead time, with the downtime each stock-out would cost.
- HACCP plan template: hazard analysis and CCP worksheetThe Codex 12 steps in one workbook: team and product, process steps checked on site, hazard analysis with the CCP decision tree, the CCP table with completeness checks, an allergen matrix and a verification schedule.
- Forklift operator training and evaluation recordPer-operator training and evaluation record, a register with three-year due dates and refresher triggers, and a weighted practical evaluation scoresheet.
- REBA worksheet (Rapid Entire Body Assessment)Score up to six postures with REBA: body-part drop-downs, Tables A, B and C as lookups, final score and action level, and a before and after comparison.
- Mock recall template: traceability exercise worksheetTrace a finished lot back to every input lot and forward to every first customer, reconcile the quantities against a tolerance and time it against your target.
- ISO 9001 internal audit checklist (production area)46 audit questions for the production floor in 11 processes, each with its ISO 9001:2015 clause, what evidence to look for and the sample to take, plus five defined grades, a findings log, a finding report and a summary by clause.
- ISO 45001 internal audit checklist44 audit questions for the plant floor in 16 safety topics, each with its ISO 45001:2018 clause, the evidence to look for and the sample to take, plus 12 worker interview prompts, a findings log and a summary by clause.
- Food plant GMP inspection checklist (21 CFR 117 subpart B)55 checks in the order of 21 CFR 117 subpart B, each citing its paragraph and saying what to look at, with a grade, finding, owner and due date; results by section and grade, a walk route and a bakery example.
- Master sanitation schedule with pre-op verificationA master list of cleaning tasks by area and equipment with frequency, chemical, lockout, who and next due date, a weekly on-time count, and the pre-operational verification log with a release step.
- Overhead crane inspection checklist: frequent and periodic34 crane checks tied to OSHA 1910.179: an operator's pre-shift card, frequent and periodic inspections with signed records, a deficiency and tag-out log, and a register of next due dates.
- Measurement uncertainty budget templateA GUM uncertainty budget: Type A and B rows, divisors by distribution, sensitivity coefficients, uc, νeff, k from the t-table, U, TUR and a guard band check.
- Maintenance job plan templateOne job planned on one sheet: steps and craft hours, parts checked against stock, tools, lockout and permits, documents, a ready check for the schedule, and technician feedback.
- Video time study filming checklistA pre-shoot checklist and shot log for filming a time study on video: camera, light, people, settings, power and review.
- OSHA compliance calendar (general industry)37 recurring federal OSHA duties with the paragraph, interval, owner, next due date and an overdue flag, plus a 12-month view and counts by owner.
- Energy use and EnPI trackerMonthly electricity, gas and fuel in one unit, a 12-month regression baseline, expected against actual energy for each month, an EnPI ratio, the running saving and the tests that say whether the model can be trusted.
- Pugh matrix templateCompare up to 8 concepts with a datum as better, same or worse on up to 12 criteria, flag must-haves, and carry the strongest into a second round.
- Machine guarding inspection sheetA machine register with due dates and a status per machine, 21 checks tied to OSHA 1910.212, .219 and .147, a guard opening check against Table O-10, and an action log.
- Condition monitoring route sheetA route of measuring points with baselines, alert and alarm limits, a check interval from the P-F interval, readings with rising and overdue flags, and an exceptions list worst first.
- Fire extinguisher inspection logOne row for every portable extinguisher: hydro test interval from OSHA Table L-1, annual and 6-year due dates, a 12-month check grid and open issues.
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A shift handover sheet, a red tag log, a changeover checklist for one machine: if your team uses it on the floor, ask.