Learning Curve Theory
The learning curve theory states that as the quantity of items produced doubles, the cost or time to produce each unit decreases at a consistent rate. This phenomenon is observed in manufacturing, assembly operations, and any repetitive task where workers become more efficient with experience.
Where:
- Y = Cumulative average time per unit
- a = Time required to produce the first unit
- X = Cumulative number of units produced
- b = Learning coefficient (log(learning rate)/log(2))
Calculation Type
Select what you want to calculate:
Calculate Time for a Specific Unit
Calculate the time required to produce a specific unit based on the learning curve.
Results
Time for Unit #
Cumulative Average Time
Total Time for All Units
Improvement from First Unit
Time per Unit
| Unit Number | Time per Unit (hours) | Cumulative Average Time | Total Time |
|---|
Calculate Total Time for Multiple Units
Calculate the total time required to produce a batch of units based on the learning curve.
Results
Total Time
Average Time per Unit
Time for First Unit in Range
Time for Last Unit in Range
Interpretation
Calculate Learning Rate
Calculate the learning rate based on time data from two different production points.
Results
Learning Rate
Learning Coefficient
Time Reduction
Interpretation
Projected Times
| When Production Doubles To | Expected Time per Unit |
|---|
Learning Curve Examples in Manufacturing
Aircraft Manufacturing
The aircraft industry often experiences an 80% learning curve. If the first aircraft requires 10,000 hours to produce, the second aircraft would take 8,000 hours (80% of 10,000), the fourth would take 6,400 hours (80% of 8,000), and so on.
Electronics Assembly
A smartphone manufacturer might have a 90% learning curve. If the first unit takes 60 minutes to assemble, the second would take 54 minutes, the fourth would take 48.6 minutes, etc.
Custom Machinery
For complex custom machinery with an 85% learning curve, if the first unit requires 500 hours, the second would take 425 hours, and the fourth would take 361.25 hours.
Typical Learning Rates by Industry
| Industry/Process | Typical Learning Rate | Explanation |
|---|---|---|
| Aerospace | 80-85% | Complex assembly processes show significant improvement with experience |
| Electronics Manufacturing | 90-95% | Highly automated processes with less room for human improvement |
| Shipbuilding | 80-85% | Large, complex projects with significant learning potential |
| Repetitive Manual Tasks | 70-80% | Tasks with high human involvement show steep learning curves |
| Highly Automated Processes | 95-100% | Little room for improvement beyond initial setup |