Use the Makeready Cost Calculator
Understanding Your Results
The Makeready Cost Calculator result is an estimating aid for the production question shown above. Interpret the output on the same quantity and waste basis used for the job ticket. Keep makeready, running spoilage, finishing loss and customer overage separate when checking the production plan.
How to Use This Calculator
- Gather the job values for Makeready sheets, Cost per sheet, Setup hours and Hourly cost.
- Keep good quantity, makeready, spoilage and customer overage on clearly separated bases.
- Select Calculate and interpret the output for Makeready Cost Calculator.
- Check the output against the intended imposition, finishing route and production allowance before releasing the job.
Formula & Methodology
Makeready cost = makeready sheets × sheet cost + setup hours × loaded hourly cost.
Assumptions & Limitations
Use practical sheet yield and a waste basis that does not count the same loss twice. Makeready, running spoilage, finishing loss and customer overage are different quantities.
Worked Example
With 350 makeready sheets at $0.18 each plus 0.75 setup hours at $120/hour, makeready cost = $63 + $90 = $153.
Common Mistakes
Do not count setup labor twice—once in hourly cost and again as a separate labor line—unless your hourly rate intentionally excludes it. Use actual sheet cost for makeready stock.
Frequently Asked Questions
Which inputs have the biggest effect on the Makeready Cost Calculator?
Makeready cost = makeready sheets × sheet cost + setup hours × loaded hourly cost. The variables named in that relationship are the first values to verify when the result changes unexpectedly.
How should I check this estimate before production?
Do not count setup labor twice—once in hourly cost and again as a separate labor line—unless your hourly rate intentionally excludes it. Use actual sheet cost for makeready stock. Compare the estimate with one completed job using the same units and quantity basis before turning a recurring variance into a shop standard.
What does the Makeready Cost Calculator result represent?
Estimate makeready cost from setup sheets, sheet cost, setup hours and loaded hourly cost. The displayed methodology explains the calculation basis; use the worked example to check that your units and quantity basis match the job.
What should I verify before using this result for production?
Use practical sheet yield and a waste basis that does not count the same loss twice. Makeready, running spoilage, finishing loss and customer overage are different quantities. Confirm the entered measurements against the job ticket, equipment limits or supplier data that apply to your plant.
How should I validate the Makeready Cost Calculator on a repeat job?
Close the job using good quantity, makeready sheets, running spoilage, finishing loss and actual run time as separate values. Recalculate on the same basis before changing a production standard.