EV & Battery Manufacturing worked example

Cell Capacity Variation Sorting Capacity at 66% capacity tester uptime: a worked example

This worked example runs the cell capacity variation sorting capacity numbers for a tougher week than the baseline: 66% capacity tester uptime instead of the typical 91%. Estimate usable capacity-screening output from cells per grading cycle, available cycles, tester uptime, and acceptable bin yield.

The inputs for this scenario

  • Cells screened per grading cycle: 900 cells/cycle (held at the documented default)
  • Available grading cycles: 24 cycles (held at the documented default)
  • Capacity tester uptime: 66 % (the input this scenario stresses; the baseline uses 91)
  • Acceptable capacity-bin yield: 95 % (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Gross capacity-screening output = cells per grading cycle × available grading cycles.
  • Usable capacity-graded cells works out to 13,543 cells at these inputs, and this is the headline figure for the scenario.
  • Gross capacity-screening output works out to 21,600 cells at these inputs.
  • Cells lost to tester downtime works out to 7,344 cells at these inputs.
  • Cells outside usable capacity bins works out to 713 cells at these inputs.

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 27.47% below the baseline at 13,543 cells.
  • Use it to plan grading capacity, feed pack build with matched cells, or size tester banks for a target cell volume. 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

  • Usable capacity-graded cells: 13,543 cells (headline result)
  • Gross capacity-screening output: 21,600 cells
  • Cells lost to tester downtime: 7,344 cells
  • Cells outside usable capacity bins: 713 cells

Run it with your numbers

  • To rerun this with your own numbers, open the live Cell Capacity Variation Sorting Capacity calculator, set capacity tester uptime to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.