Production calculator
Bottleneck Capacity Calculator
Turn several process cycle times into one constraint-based capacity number adjusted for uptime and yield.
What this calculator does
- Find the limiting process step and the good-unit capacity it allows for a line or cell.
- Use before adding labor, overtime, or equipment to confirm which step constrains output.
- Finds the slowest process step and calculates the good daily capacity that constraint allows after uptime and yield.
Formula used
- Bottleneck cycle = longest process step cycle time
- Gross capacity = available seconds ÷ bottleneck cycle
- Good capacity = gross capacity × uptime × yield
Inputs explained
- Step 1 cycle time: undefined
- Step 2 cycle time: undefined
- Step 3 cycle time: undefined
- Step 4 cycle time: undefined
- Hours per shift: undefined
- Shifts per day: undefined
- Expected uptime: undefined
- Expected yield: undefined
How to use the result
- Use it before adding overtime, labor, conveyors, or equipment to make sure the real constraint is understood.
- The result assumes the longest entered cycle remains the constraint; starvation, blocking, and shared resources can move the bottleneck elsewhere.
Common questions
- What is the Bottleneck Capacity calculator for? It identifies the longest process cycle and uses it to estimate gross and good units per day for the line or cell.
- What information do I need before using it? Enter cycle times for the key process steps, hours per shift, shifts per day, expected uptime, and expected yield.
- How can I use the bottleneck capacity result? Use it to decide whether to improve the slowest step, add a parallel station, protect the constraint with buffer, or adjust the production promise.
- When is the result only an estimate? It is only an estimate when cycle times vary widely, product mix changes, or the line is often starved or blocked rather than limited by the slowest step.
Last reviewed 2026-05-12.