Bearings, Gears & Power Transmission worked example

Gear Ratio Variant Build Capacity at 97% changeover-adjusted uptime: a worked example

This scenario runs the gear ratio variant build capacity calculation on the strong side: 97% changeover-adjusted uptime, with every other input held at its documented default. a gearbox OEM needs to confirm whether the line can build the required mix of reducer ratios, gearsets, or drive variants

The inputs for this scenario

  • Ratio builds per cycle: 6 builds/cycle (unchanged)
  • Available ratio build cycles: 96 cycles (unchanged)
  • Changeover-adjusted uptime: 97 % (raised for this scenario; the documented default is 84)
  • First-pass ratio configuration yield: 95 % (unchanged)

Working through the calculation

  • Applying the documented formula (Gross ratio builds scheduled = ratio builds per cycle × available ratio build cycles) to the inputs above produces each figure below.
  • At this operating point the engine returns 531 builds for accepted gear ratio build capacity, the number this scenario is built around.
  • At this operating point the engine returns 576 builds for gross ratio builds scheduled.
  • At this operating point the engine returns 17.28 builds for builds lost to changeover downtime.
  • At this operating point the engine returns 27.94 builds for builds requiring configuration rework.

How this compares with the baseline

  • Against the tool's baseline example, where changeover-adjusted uptime sits at 84% and the headline result is 460 builds, this scenario comes in 15.48% above the baseline at 531 builds.
  • Use it when committing build quantities for a high-mix gear-ratio run where frequent changeovers and configuration failures eat into the schedule. Treat this as a target state: the delta against the baseline quantifies what the improvement is worth before you commit to chasing it.

Results at a glance

  • Accepted gear ratio build capacity: 531 builds (headline result)
  • Gross ratio builds scheduled: 576 builds
  • Builds lost to changeover downtime: 17.28 builds
  • Builds requiring configuration rework: 27.94 builds

Run it with your numbers

  • Every input above is editable in the live Gear Ratio Variant Build Capacity calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.