Commercial Vehicle, Bus & Coach Manufacturing worked example

Option Complexity at 90% option control effectiveness: a worked example

This scenario runs the option complexity calculation on the strong side: 90% option control effectiveness, with every other input held at its documented default. reviewing option complexity across mixed-model vehicle builds

The inputs for this scenario

  • Customer option instances built: 145 units (unchanged)
  • Mixed-model production period: 40 hr (unchanged)
  • Option control effectiveness: 90 % (raised for this scenario; the documented default is 78)

Working through the calculation

  • Applying the documented formula (Gross option complexity = customer option instances built รท mixed-model production period) to the inputs above produces each figure below.
  • At this operating point the engine returns 3.26 vehicles / hr for effective throughput, the number this scenario is built around.
  • At this operating point the engine returns 3.63 vehicles / hr for raw throughput.
  • At this operating point the engine returns 90 % for efficiency.
  • At this operating point the engine returns 40 hr for mixed-model production period.

How this compares with the baseline

  • Against the tool's baseline example, where option control effectiveness sits at 78% and the headline result is 2.83 vehicles / hr, this scenario comes in 15.38% above the baseline at 3.26 vehicles / hr.
  • Use it when assessing how a high-mix order book or a proposed new option affects realistic line speed, or when building the case for kitting or modular design. 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

  • Effective throughput: 3.26 vehicles / hr (headline result)
  • Raw throughput: 3.63 vehicles / hr
  • Efficiency: 90 %
  • mixed-model production period: 40 hr

Run it with your numbers

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

Last reviewed 2026-05-12.