What makes ratio builds different from a standard build?

Each different ratio needs its own gears, spacing, documentation and test program, so changeovers and configuration mistakes take a share that a single-variant line does not pay.

How is configuration yield measured?

Count builds that pass the ratio audit with the right gears and settings the first time, divided by the builds that entered the audit. It is a first-pass measure, so later rework does not count.

Does uptime include planned breaks?

Use the uptime your line actually delivers after breaks, ratio changes and short stops. Planned breaks are already in the available cycles you enter.

What if the target exceeds accepted builds?

The page reports the shortfall. Recover it by cutting changeover time, adding ratio build cycles, or fixing the configuration errors that drive rework.

Bearings, Gears & Power Transmission calculator

Gear Ratio Variant Build Capacity Calculator

Estimate how many ratio variants the assembly line can complete after changeovers and configuration errors take their share. Gross builds come from the cycle plan; uptime and yield decide how many are accepted.

What this calculator does

Accepted gear ratio build capacity from builds per cycle, cycles, changeover-adjusted uptime and configuration yield.

Formula used

Gross ratio builds scheduled = ratio builds per cycle × available ratio build cycles
Accepted gear ratio build capacity = gross ratio builds × changeover-adjusted uptime ÷ 100 × first-pass configuration yield ÷ 100
Builds lost to changeover = gross ratio builds × (100 − changeover-adjusted uptime) ÷ 100
Builds requiring configuration rework = gross ratio builds × uptime ÷ 100 × (100 − configuration yield) ÷ 100
Shortfall to target = target accepted builds − accepted gear ratio build capacity

Inputs explained

Ratio Builds per Cycle: Ratio builds completed in one assembly cycle, from the line balance.
Available Ratio Build Cycles: Build cycles available in the period, from the production schedule.
Changeover-Adjusted Uptime: Uptime after ratio changeovers and interruptions, from the line log.
First-Pass Ratio Configuration Yield: Share built right the first time, from the configuration audit.
Target Accepted Builds: Accepted builds the schedule needs, from the build plan.

How to use the result

Best suited to committing a high-mix ratio build schedule, sizing buffers for ratio changeovers, checking variant output against a target.
This counts gear ratio builds only; belt and chain drive packages need their own speed and capacity rules (N3, N4). A single blended yield hides configuration errors that repeat on one variant.

Current U.S. benchmarks

The U.S. has 21,668 machinery manufacturing establishments employing about 1,086,146 workers (Census County Business Patterns, 2023).

Common questions

What makes ratio builds different from a standard build? Each different ratio needs its own gears, spacing, documentation and test program, so changeovers and configuration mistakes take a share that a single-variant line does not pay.
How is configuration yield measured? Count builds that pass the ratio audit with the right gears and settings the first time, divided by the builds that entered the audit. It is a first-pass measure, so later rework does not count.
Does uptime include planned breaks? Use the uptime your line actually delivers after breaks, ratio changes and short stops. Planned breaks are already in the available cycles you enter.
What if the target exceeds accepted builds? The page reports the shortfall. Recover it by cutting changeover time, adding ratio build cycles, or fixing the configuration errors that drive rework.

Last reviewed 2026-10-01.