Bearings, Gears & Power Transmission worked example

Gear Ratio Variant Build Capacity at 60% changeover-adjusted uptime: a worked example

This worked example runs the gear ratio variant build capacity numbers for a tougher week than the baseline: 60% changeover-adjusted uptime instead of the typical 84%. Estimate accepted gearbox or gearset variant output from ratio builds per cycle, available cycles, changeover uptime, and first-pass configuration yield.

The inputs for this scenario

  • Ratio builds per cycle: 6 builds/cycle (held at the documented default)
  • Available ratio build cycles: 96 cycles (held at the documented default)
  • Changeover-adjusted uptime: 60 % (the input this scenario stresses; the baseline uses 84)
  • First-pass ratio configuration yield: 95 % (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Gross ratio builds scheduled = ratio builds per cycle × available ratio build cycles.
  • Accepted gear ratio build capacity works out to 328 builds at these inputs, and this is the headline figure for the scenario.
  • Gross ratio builds scheduled works out to 576 builds at these inputs.
  • Builds lost to changeover downtime works out to 230 builds at these inputs.
  • Builds requiring configuration rework works out to 17.28 builds at these inputs.

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 28.57% below the baseline at 328 builds.
  • Use it when committing build quantities for a high-mix gear-ratio run where frequent changeovers and configuration failures eat into the schedule. 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

  • Accepted gear ratio build capacity: 328 builds (headline result)
  • Gross ratio builds scheduled: 576 builds
  • Builds lost to changeover downtime: 230 builds
  • Builds requiring configuration rework: 17.28 builds

Run it with your numbers

  • To rerun this with your own numbers, open the live Gear Ratio Variant Build Capacity calculator, set changeover-adjusted uptime to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.