Appliances, HVAC & White Goods Manufacturing worked example

Leak Test Workload Calculator at 13% retest and handling allowance: a worked example

This worked example runs the leak test workload calculator numbers for a tougher week than the baseline: 13% retest and handling allowance instead of the typical 18%. Calculate leak-test hours required from appliance or HVAC units tested, leak-test rate, and allowance for retest and handling.

The inputs for this scenario

  • Units or assemblies leak tested: 1,600 units (held at the documented default)
  • Leak-test throughput rate: 2.4 units / min (held at the documented default)
  • Retest and handling allowance: 13 % (the input this scenario stresses; the baseline uses 18)

Working through the calculation

  • The calculation starts from the formula this tool documents: Base leak-test time = units or assemblies leak tested รท leak-test throughput rate.
  • Required leak-test workload works out to 753 hr at these inputs, and this is the headline figure for the scenario.
  • Base leak-test time works out to 667 hr at these inputs.
  • Retest and handling allowance works out to 13 % at these inputs.
  • Leak-test throughput rate works out to 2.4 units / min at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where retest and handling allowance sits at 18% and the headline result is 787 hr, this scenario comes in 4.24% below the baseline at 753 hr.
  • Use it for shift staffing, capacity planning, and deciding whether to add a second leak-test station before a volume ramp. A result at this level usually justifies acting on the stressed input before touching anything else, because every other figure in the table is downstream of it.

Results at a glance

  • Required leak-test workload: 753 hr (headline result)
  • Base leak-test time: 667 hr
  • Retest and handling allowance: 13 %
  • Leak-test throughput rate: 2.4 units / min

Run it with your numbers

  • To rerun this with your own numbers, open the live Leak Test Workload Calculator calculator, set retest and handling allowance to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.