Commercial Vehicle, Bus & Coach Manufacturing worked example

Water Leak Test Capacity at 65% water test booth availability: a worked example

Here is what the math looks like when conditions slip. We hold every other input steady and drop water test booth availability to 65%, then walk the calculation through step by step. Estimate water leak test capacity for buses, coaches, vans, shuttles, or specialty vehicle bodies.

The inputs for this scenario

  • Vehicles tested per water booth cycle: 1 units / cycle (held at the documented default)
  • Planned water leak test cycles: 30 cycles (held at the documented default)
  • Water test booth availability: 65 % (the input this scenario stresses; the baseline uses 90)
  • First-pass water leak test yield: 88 % (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Gross water leak test capacity = vehicles tested per water booth cycle × planned water leak test cycles.
  • usable water leak test capacity works out to 17.16 vehicles at these inputs, and this is the headline figure for the scenario.
  • gross water leak test capacity works out to 30 vehicles at these inputs.
  • water leak test capacity lost to downtime works out to 10.5 vehicles at these inputs.
  • water leak test capacity lost to retest or rework works out to 2.34 vehicles at these inputs.

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 27.78% below the baseline at 17.16 vehicles.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to water test booth availability, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. It treats yield loss as fully lost capacity, but a leaker that only needs a quick reseal may re-enter faster than a full cycle, so usable capacity can be slightly conservative.

Results at a glance

  • usable water leak test capacity: 17.16 vehicles (headline result)
  • gross water leak test capacity: 30 vehicles
  • water leak test capacity lost to downtime: 10.5 vehicles
  • water leak test capacity lost to retest or rework: 2.34 vehicles

Run it with your numbers

  • To rerun this with your own numbers, open the live Water Leak Test Capacity calculator, set water test booth availability to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.