EV & Battery Manufacturing worked example

Cell Capacity Variation Sorting Capacity at 99% capacity tester uptime: a worked example

Push capacity tester uptime up to 99% and the picture changes. This example computes every intermediate figure at that operating point. a grading or test team needs to know whether capacity screening can keep up with formation and module assembly

The inputs for this scenario

  • Cells screened per grading cycle: 900 cells/cycle (unchanged)
  • Available grading cycles: 24 cycles (unchanged)
  • Capacity tester uptime: 99 % (raised for this scenario; the documented default is 91)
  • Acceptable capacity-bin yield: 95 % (unchanged)

Working through the calculation

  • Applying the documented formula (Gross capacity-screening output = cells per grading cycle × available grading cycles) to the inputs above produces each figure below.
  • At this operating point the engine returns 20,315 cells for usable capacity-graded cells, the number this scenario is built around.
  • At this operating point the engine returns 21,600 cells for gross capacity-screening output.
  • At this operating point the engine returns 216 cells for cells lost to tester downtime.
  • At this operating point the engine returns 1,069 cells for cells outside usable capacity bins.

How this compares with the baseline

  • Against the tool's baseline example, where capacity tester uptime sits at 91% and the headline result is 18,673 cells, this scenario comes in 8.79% above the baseline at 20,315 cells.
  • It computes usable capacity-graded cells by multiplying gross screening output by tester uptime and acceptable bin yield. The value of this scenario is the size of the gap it exposes: that gap, priced out over a year, is the budget you can justify spending to close it.

Results at a glance

  • Usable capacity-graded cells: 20,315 cells (headline result)
  • Gross capacity-screening output: 21,600 cells
  • Cells lost to tester downtime: 216 cells
  • Cells outside usable capacity bins: 1,069 cells

Run it with your numbers

  • Every input above is editable in the live Cell Capacity Variation Sorting Capacity calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.