Commercial Vehicle, Bus & Coach Manufacturing worked example

Water Leak Test Capacity at 99% water test booth availability: a worked example

This scenario runs the water leak test capacity calculation on the strong side: 99% water test booth availability, with every other input held at its documented default. planning vehicle water leak test throughput

The inputs for this scenario

  • Vehicles tested per water booth cycle: 1 units / cycle (unchanged)
  • Planned water leak test cycles: 30 cycles (unchanged)
  • Water test booth availability: 99 % (raised for this scenario; the documented default is 90)
  • First-pass water leak test yield: 88 % (unchanged)

Working through the calculation

  • Applying the documented formula (Gross water leak test capacity = vehicles tested per water booth cycle × planned water leak test cycles) to the inputs above produces each figure below.
  • At this operating point the engine returns 26.14 vehicles for usable water leak test capacity, the number this scenario is built around.
  • At this operating point the engine returns 30 vehicles for gross water leak test capacity.
  • At this operating point the engine returns 0.3 vehicles for water leak test capacity lost to downtime.
  • At this operating point the engine returns 3.56 vehicles for water leak test capacity lost to retest or rework.

How this compares with the baseline

  • Against the tool's baseline example, where water test booth availability sits at 90% and the headline result is 23.76 vehicles, this scenario comes in 10% above the baseline at 26.14 vehicles.
  • Use it when planning a shift or week at the water-test gate, or checking whether the booth can keep pace with line output. 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

  • usable water leak test capacity: 26.14 vehicles (headline result)
  • gross water leak test capacity: 30 vehicles
  • water leak test capacity lost to downtime: 0.3 vehicles
  • water leak test capacity lost to retest or rework: 3.56 vehicles

Run it with your numbers

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

Last reviewed 2026-05-12.