Cut-to-Box Lead Time & Stage WIP Velocity Calculator

The formula

This is the expression the tool evaluates. Every term is named underneath, with the unit it must be supplied in.

How the result is derived

Step by step, from the values you type to the figure on screen.

1. The 6 inputs are read from the form on every keystroke: Cutting & Bundling WIP, Sewing WIP, Finishing WIP, Packing WIP, Packed Output and Working Hours per Day.
2. Each value is checked against the accepted range in the input table below. A value outside its range stops the calculation rather than producing a misleading figure — the results blank out and a message appears.
3. The validated values are substituted into the expression above, which resolves Cut-to-Box Lead Time together with every supporting figure in one pass — no value is carried over from a previous entry.
4. The supporting outputs — Cutting Dwell, Sewing Dwell, Finishing Dwell, Packing Dwell, Largest Stage Share of WIP and Lead Time — come from the same pass, so they always describe the same case as the headline figure.
5. Results are rounded for display only. The full-precision value is used throughout the chain, so reading a rounded intermediate figure back into the tool by hand can shift the last digit.

What each input means

Where to read each value on the floor, the unit it must be in, and the range the tool accepts.

What the tool returns

The headline figure and every supporting value it is built from.

Worked example

The tool loads with this case already solved — the Cut-to-Box Lead Time shown above is its answer. Change one value and the difference from this baseline is the sensitivity of the result to that variable.

How to use it

1. Work through the input groups in order — Work in Progress and Flow. The defaults are a realistic case, so you can change one value at a time and watch what moves.
2. There is no calculate button. Every figure recalculates as you type or drag, which is what makes this usable for a what-if sweep rather than a single answer.
3. Read Cut-to-Box Lead Time in the dark results panel — that is the headline figure, expressed in days.
4. Check the supporting rows underneath (Cutting Dwell, Sewing Dwell, Finishing Dwell, Packing Dwell, Largest Stage Share of WIP and Lead Time) before acting on the headline — they are where an implausible input usually shows itself first.
5. Reset to defaults returns every field to the reference case, which is the quickest way to check whether a surprising result came from the tool or from an input you had changed earlier.

Where this is used

• Process planning — establishing Cut-to-Box Lead Time before a trial is booked, so machine time and material in Industrial Engineering, Time & Motion are committed against a calculated figure rather than an estimate.
• Costing and quotation — Cut-to-Box Lead Time is an input to the cost sheet, and quoting from a worked number rather than a remembered one is what keeps a margin intact.
• Troubleshooting — when the floor result drifts from plan, entering the measured values (starting with Cutting & Bundling WIP) shows how much of the gap in Cut-to-Box Lead Time each variable explains.
• Teaching and study — the accepted ranges bracket normal Industrial Engineering, Time & Motion practice, so moving one variable at a time shows the shape of the relationship rather than a single answer.

Assumptions and limits

• Little's Law needs a system in steady state, so a count taken while a large order is being launched or run out will mislead — take WIP at the same point in the week, repeatedly, before drawing conclusions. Throughput must also be measured at the exit, since counting output at sewing while WIP accumulates in finishing produces a lead time shorter than reality. The largest stage holds the most inventory but is not automatically the constraint: a stage can hold WIP because it is slow, or because the stage after it is, and only watching whether the queue grows or shrinks distinguishes the two.
• Every input is bounded to the range normal practice occupies (Cutting & Bundling WIP 0 to 500000 pcs, Sewing WIP 0 to 500000 pcs and Finishing WIP 0 to 500000 pcs, and so on for the rest). Those bounds are guard rails against typing errors, not a claim that the formula fails one unit outside them.
• The calculation is deterministic: the same inputs always give the same result. It carries no allowance for machine condition, operator skill, ambient conditions or lot-to-lot material variation unless an input above explicitly represents one.
• Nothing is sent anywhere. The maths runs in your browser, so the numbers you type never leave the page.

Questions people ask