EV & Battery Manufacturing worked example

Battery Pack Leak Test Capacity at 65% leak-test station uptime: a worked example

Suppose leak-test station uptime falls to 65%. This page works the full calculation at that level so you can see exactly which result moves and by how much. Estimate usable pack leak-test capacity from packs per cycle, available cycles, test uptime, and first-pass leak yield.

The inputs for this scenario

  • Packs tested per leak-test cycle: 2 packs/cycle (held at the documented default)
  • Available leak-test cycles in period: 220 cycles (held at the documented default)
  • Leak-test station uptime: 65 % (the input this scenario stresses; the baseline uses 90)
  • First-pass leak-test yield: 97 % (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Gross leak-test capacity = packs tested per cycle × available leak-test cycles.
  • Good leak-tested pack capacity works out to 277 packs at these inputs, and this is the headline figure for the scenario.
  • Gross leak-test capacity works out to 440 packs at these inputs.
  • Packs lost to leak-test downtime works out to 154 packs at these inputs.
  • Packs lost to leak-test failures works out to 8.58 packs at these inputs.

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 27.78% below the baseline at 277 packs.
  • It computes good leak-tested pack capacity as packs per cycle times available cycles, derated by station uptime and first-pass yield. When the numbers land here, the stressed input is the lever to work; the walkthrough above shows exactly how much each output recovers as it climbs back toward the baseline.

Results at a glance

  • Good leak-tested pack capacity: 277 packs (headline result)
  • Gross leak-test capacity: 440 packs
  • Packs lost to leak-test downtime: 154 packs
  • Packs lost to leak-test failures: 8.58 packs

Run it with your numbers

  • To rerun this with your own numbers, open the live Battery Pack Leak Test Capacity calculator, set leak-test station uptime to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.