Commercial Vehicle, Bus & Coach Manufacturing worked example

Line Balance at 94% line balance efficiency: a worked example in commercial vehicle, bus & coach manufacturing

What does the result look like when line balance efficiency reaches 94%? The full calculation is worked below with real intermediate numbers. checking vehicle assembly line balance and output

The inputs for this scenario

  • Completed vehicles or body sets: 34 units (unchanged)
  • Available line production time: 8 hr (unchanged)
  • Line balance efficiency: 94 % (raised for this scenario; the documented default is 82)

Working through the calculation

  • Applying the documented formula (Gross line balance = completed vehicles or body sets รท available line production time) to the inputs above produces each figure below.
  • At this operating point the engine returns 3.99 vehicles / hr for effective throughput, the number this scenario is built around.
  • At this operating point the engine returns 4.25 vehicles / hr for raw throughput.
  • At this operating point the engine returns 94 % for efficiency.
  • At this operating point the engine returns 8 hr for available line production time.

How this compares with the baseline

  • Against the tool's baseline example, where line balance efficiency sits at 82% and the headline result is 3.49 vehicles / hr, this scenario comes in 14.63% above the baseline at 3.99 vehicles / hr.
  • A figure at this level is achievable when line balance efficiency is genuinely sustained, not just peaked for a shift. It assumes a single efficiency figure captures all balance loss; it does not locate the bottleneck station or distinguish balance loss from downtime, scrap, or starvation.

Results at a glance

  • Effective throughput: 3.99 vehicles / hr (headline result)
  • Raw throughput: 4.25 vehicles / hr
  • Efficiency: 94 %
  • available line production time: 8 hr

Run it with your numbers

  • Every input above is editable in the live Line Balance calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.