EV & Battery Manufacturing worked example

Battery Pack Leak Test Capacity at 99% leak-test station uptime: a worked example

What does the result look like when leak-test station uptime reaches 99%? The full calculation is worked below with real intermediate numbers. a pack line needs to confirm helium, pressure-decay, or coolant-loop leak testing can keep up with assembly takt

The inputs for this scenario

  • Packs tested per leak-test cycle: 2 packs/cycle (unchanged)
  • Available leak-test cycles in period: 220 cycles (unchanged)
  • Leak-test station uptime: 99 % (raised for this scenario; the documented default is 90)
  • First-pass leak-test yield: 97 % (unchanged)

Working through the calculation

  • Applying the documented formula (Gross leak-test capacity = packs tested per cycle × available leak-test cycles) to the inputs above produces each figure below.
  • At this operating point the engine returns 423 packs for good leak-tested pack capacity, the number this scenario is built around.
  • At this operating point the engine returns 440 packs for gross leak-test capacity.
  • At this operating point the engine returns 4.4 packs for packs lost to leak-test downtime.
  • At this operating point the engine returns 13.07 packs for packs lost to leak-test failures.

How this compares with the baseline

  • Against the tool's baseline example, where leak-test station uptime sits at 90% and the headline result is 384 packs, this scenario comes in 10% above the baseline at 423 packs.
  • A figure at this level is achievable when leak-test station uptime is genuinely sustained, not just peaked for a shift. It applies a single first-pass yield and ignores retest loops; packs that fail and are reworked then re-tested can either recover or further consume cycles, which this single-pass model does not capture.

Results at a glance

  • Good leak-tested pack capacity: 423 packs (headline result)
  • Gross leak-test capacity: 440 packs
  • Packs lost to leak-test downtime: 4.4 packs
  • Packs lost to leak-test failures: 13.07 packs

Run it with your numbers

  • Every input above is editable in the live Battery Pack Leak Test Capacity calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.