SyteLine Job Lead Time Calculator
Lead time values on SyteLine items and routings feed planned order dates, quoted delivery dates and MRP offsets. This calculator builds the number from its parts so you can see what is real processing and what is waiting.
Your numbers
Your results
Assumes operations run one after another with no overlap or lot splitting, and the same data for every operation. Real schedules depend on finite capacity.
Manufacturing lead time vs lot size
Sweeps Lot size from 1 to 1000, holding your other inputs fixed.
Lead time reality check
Optional: we can compare the planned lead times in your system with actual closed job durations.
Optional. The tool and every export work without this. No spam.
How to use it
Enter the lot size, number of operations and average setup and run time per operation. Efficiency scales run time up to allow for stoppages and slow runs. Add the typical queue time before each operation and move or wait time after it. The result is total manufacturing lead time in days and the share of that time spent in actual processing. Use the chart to see how lot size changes the answer.
- Take queue time from observed shop data, not wishful targets
- Use the average of operations if they differ little
- Run twice, with and without lot splitting, to compare
The model
Per operation, elapsed time equals setup plus run hours divided by productive hours per day, plus queue and move days. Total lead time multiplies that by the number of operations. Queue is usually the largest term, often 80% or more of lead time in a job shop, which is why shortening setup alone rarely cuts delivery time much. Reducing queue through load leveling and smaller releases usually pays more.
Using the result
Compare the figure with the lead time stored on the item and the offsets that MRP uses. If the stored number is much shorter, planned orders will be late; if much longer, you carry unneeded inventory. For quotes, add a buffer for material procurement. For lots that are large relative to run rate, overlapping operations or splitting the lot can cut elapsed time, which this simple model does not capture.
- Re-check after large changes in shop load
- Separate purchased lead time from manufacturing lead time
- Track actual start to finish dates on closed jobs
Frequently Asked Questions
Why is the value adding share so low?
In most job shops material spends the majority of its time waiting between operations. A share of 10 to 30% is common, and it shows where improvement effort should go.
Is this the same as cycle time?
No. Cycle time is the time to produce one unit at a station. Lead time includes setup, queue, move and wait across the whole routing.
Should efficiency be applied to setup too?
Here it only scales run time. If setup also overruns, increase the setup hours input to the observed average.
How does this relate to MRP offsets?
MRP backs planned order start dates off the need date using lead time. If the stored lead time is wrong, every planned date will be wrong.
If you would like actual job start to finish times pulled from SyteLine and compared with the lead times planning uses, we can produce that comparison.
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