Commercial Vehicle, Bus & Coach Manufacturing worked example

Road Test Capacity at 99% road-test availability: a worked example

What does the result look like when road-test availability reaches 99%? The full calculation is worked below with real intermediate numbers. planning finished vehicle road-test capacity

The inputs for this scenario

  • Vehicles completed per road-test cycle: 2 units / cycle (unchanged)
  • Planned road-test cycles: 24 cycles (unchanged)
  • Road-test availability: 99 % (raised for this scenario; the documented default is 88)
  • First-pass road-test yield: 92 % (unchanged)

Working through the calculation

  • Applying the documented formula (Gross road test capacity = vehicles completed per road-test cycle × planned road-test cycles) to the inputs above produces each figure below.
  • At this operating point the engine returns 43.72 vehicles for usable road test capacity, the number this scenario is built around.
  • At this operating point the engine returns 48 vehicles for gross road test capacity.
  • At this operating point the engine returns 0.48 vehicles for road test capacity lost to downtime.
  • At this operating point the engine returns 3.8 vehicles for road test capacity lost to retest or rework.

How this compares with the baseline

  • Against the tool's baseline example, where road-test availability sits at 88% and the headline result is 38.86 vehicles, this scenario comes in 12.5% above the baseline at 43.72 vehicles.
  • A figure at this level is achievable when road-test availability is genuinely sustained, not just peaked for a shift. It assumes one retest absorbs a full slot — heavy rework loops or weather-dependent track closures can erode real capacity below this estimate.

Results at a glance

  • usable road test capacity: 43.72 vehicles (headline result)
  • gross road test capacity: 48 vehicles
  • road test capacity lost to downtime: 0.48 vehicles
  • road test capacity lost to retest or rework: 3.8 vehicles

Run it with your numbers

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

Last reviewed 2026-05-12.