Free tools
Free lean manufacturing calculators
The numbers lean teams work out every week: OEE, the cost of downtime, changeover time, takt, cycle and lead time, line balance, first pass yield, the cost of poor quality, process capability (Cp and Cpk) and MTBF with MTTR. Each shows its formula and a worked example, updates as you type, and gives you a link to share the result. The ROI calculator estimates what waste costs your plant. All free, with no sign-up.
OEE calculator
Overall equipment effectiveness from shift time, downtime, ideal cycle time and part counts.
- OEE
- Availability
- Performance
- Quality
Downtime cost calculator
What an hour, an event and a year of unplanned downtime cost, from lost output, idle labour, scrap and overtime.
- Cost per hour
- Cost per event
- Cost per year
SMED changeover calculator
Time saved by moving changeover steps from internal to external, capacity freed per week and the smaller batch it allows.
- New changeover time
- Capacity freed
- Smaller batch size
Takt time calculator
The pace a line must hit to meet customer demand, from shift time, breaks and daily demand.
- Takt time
- Units per hour
- Available time
Cycle time calculator
Cycle time against takt, units per hour, capacity per shift and the gap to daily demand.
- Cycle vs takt
- Units per hour
- Gap to demand
Line balancing calculator
Line efficiency, balance delay and the minimum number of stations from station times and takt.
- Line efficiency
- Balance delay
- Minimum stations
First pass yield (FPY) calculator
First pass yield at each step and rolled throughput yield (RTY) across the whole process.
- FPY per step
- Rolled throughput yield
- Lowest step
Cost of poor quality (COPQ) calculator
Total COPQ and cost of quality, and each as a share of revenue, from the four quality cost categories.
- COPQ
- % of revenue
- Cost of quality
Process capability (Cp, Cpk) calculator
Cp and Cpk against your specification limits, plus Pp and Ppk from pasted measurements, with a distribution chart.
- Cpk
- Cp
- Pp and Ppk
- Expected ppm out of spec
MTBF and MTTR calculator
Mean time between failures, mean time to repair and availability from operating time, failures and repair time.
- MTBF
- MTTR
- Availability
Lead time calculator
Manufacturing lead time from WIP and throughput (Little's Law), and the share of it that adds value.
- Lead time
- Value-added ratio
- Non-value-added time
Manufacturing ROI calculator
Answer a few questions about your shop floor, shifts and downtime to estimate your potential ROI with LeanSuite.
- Estimated annual waste
- Recoverable savings
Built to be checked, shared and reused
Formula and worked example
Every calculator here except the ROI calculator shows the formula it uses and a worked example you can check by hand.
Shareable results
Copy a link that opens the calculator with your numbers already in, or copy the result as text.
Free to embed
Put any of these calculators except the ROI calculator on your own site, course page or intranet with a short code snippet.
New to a term? The lean glossary defines OEE, SMED, takt time, cycle time, lead time, line balancing, COPQ, process capability, MTBF and more, and the Learn hub has the guides behind them.