Cycle Time & Cost Estimator.
Estimate ₹/part for any machined component. Includes setup, run time, labor, machine overhead, tooling, and material. Built for Indian shop floors.
●Time
●Labor & machine
●Material & tooling
●Overhead & margin
Batch summary
Cycle Time and Cost Estimation
Accurate cycle time and per-part cost estimation is the difference between profitable jobs and money-losing jobs. This calculator combines all the factors — setup, run, material, labor, overhead, profit — into a single quotable number.
Cost Per Part Formula
Total time/part = (Setup / Batch) + (Run + Load)/Efficiency
Subtotal = Material + Setup + Labor + Machine + Tooling
Cost = Subtotal × (1 + Overhead) × (1 + SG&A)
Quote = Cost × (1 + Profit margin)
Worked Example
Quoting a batch of 100 milled aluminum brackets.
- Setup: 60 min, Run: 5 min/part, Load: 1 min/part, Efficiency: 85%
- Operator: ₹200/hr × 1, Machine: ₹600/hr
- Material: ₹50/part (with 90% yield → ₹55.5)
- Tool wear: ₹8/part, Consumables: ₹5/part
- Overhead: 35%, SG&A: 10%, Profit: 15%
- Setup/part = 60/100 = 0.6 min, Cycle = (5+1)/0.85 = 7.06 min → 7.66 min/part
- Setup cost = (0.6/60)(200+600) = ₹8.0/part
- Labor = (7.06/60)(200) = ₹23.5/part, Machine = (7.06/60)(600) = ₹70.6/part
- Subtotal = 55.5 + 8.0 + 23.5 + 70.6 + 13.0 = ₹170.6
- + Overhead (35%) = ₹230.3 → + SG&A (10%) = ₹253.3 → + Profit (15%) = ₹291.3/part
What Most Quotes Miss
- Efficiency < 100% — real-world OEE is 60-85%. A "5-min cycle" actually takes 6-8 min on the floor.
- Setup amortization — 60-min setup over 100 parts = 0.6 min/part. Over 10 parts = 6 min/part. Volume matters.
- Tool wear cost — carbide endmills are ₹500-2000 each. Track parts-per-tool.
- SG&A — sales, admin, finance overhead. Often forgotten by job shops.
Improving Cycle Time
- Faster speeds/feeds — use the Speeds & Feeds calculator to optimize.
- Reduce changeover — SMED methods can cut setup 50%+.
- Improve OEE — see OEE Calculator for systematic loss analysis.
- Automation — pallet changers, bar feeders, robotic loading reduce load time.
Related Tools
For matching cycle time to demand, see Takt Time Calculator. For capacity utilization, see OEE Calculator. To quantify defect costs, use Cost of Poor Quality. For quoting workflow, use CadNexa ROI.