Bicycles, E-Bikes & Micromobility worked example

Vehicle Capacity Gap at 63% assembly station uptime: a worked example

This worked example runs the vehicle capacity gap numbers for a tougher week than the baseline: 63% assembly station uptime instead of the typical 88%. Estimate good bicycle, e-bike, or scooter output capacity from station output, available production cycles, uptime, and first-pass yield.

The inputs for this scenario

  • Vehicles completed per cycle: 12 vehicles / cycle (held at the documented default)
  • Available production cycles: 85 cycles (held at the documented default)
  • Assembly station uptime: 63 % (the input this scenario stresses; the baseline uses 88)
  • Vehicle first-pass yield: 96 % (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Gross scheduled vehicle capacity = vehicles completed per cycle × available production cycles.
  • Good vehicle capacity works out to 617 vehicles at these inputs, and this is the headline figure for the scenario.
  • Gross scheduled vehicle capacity works out to 1,020 vehicles at these inputs.
  • Vehicle capacity lost to downtime works out to 377 vehicles at these inputs.
  • Vehicle capacity lost to defects works out to 25.7 vehicles at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where assembly station uptime sits at 88% and the headline result is 862 vehicles, this scenario comes in 28.41% below the baseline at 617 vehicles.
  • Use it when committing build volumes, sizing a line for a new model, or diagnosing whether a shortfall is a downtime or a quality problem. 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

  • Good vehicle capacity: 617 vehicles (headline result)
  • Gross scheduled vehicle capacity: 1,020 vehicles
  • Vehicle capacity lost to downtime: 377 vehicles
  • Vehicle capacity lost to defects: 25.7 vehicles

Run it with your numbers

  • To rerun this with your own numbers, open the live Vehicle Capacity Gap calculator, set assembly station uptime to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.