Consumer Goods & Durable Products Manufacturing worked example

End-of-Line Test Throughput at 99% test station uptime: a worked example

Push test station uptime up to 99% and the picture changes. This example computes every intermediate figure at that operating point. checking whether inspection or test is the bottleneck before pack-out or shipment

The inputs for this scenario

  • Units completed per test cycle: 4 units / cycle (unchanged)
  • Planned end-of-line test cycles per shift: 155 cycles (unchanged)
  • Test station uptime: 99 % (raised for this scenario; the documented default is 88)
  • End-of-line first-pass yield: 97 % (unchanged)

Working through the calculation

  • Applying the documented formula (Gross end-of-line test capacity = units completed per test cycle × planned end-of-line test cycles) to the inputs above produces each figure below.
  • At this operating point the engine returns 595 units for good tested units per shift, the number this scenario is built around.
  • At this operating point the engine returns 620 units for gross end-of-line test capacity.
  • At this operating point the engine returns 6.2 units for tested units lost to station downtime.
  • At this operating point the engine returns 18.41 units for tested units lost to test or inspection rejects.

How this compares with the baseline

  • Against the tool's baseline example, where test station uptime sits at 88% and the headline result is 529 units, this scenario comes in 12.5% above the baseline at 595 units.
  • It computes good tested units per shift as units-per-cycle times planned cycles, then derated by station uptime and first-pass yield. The value of this scenario is the size of the gap it exposes: that gap, priced out over a year, is the budget you can justify spending to close it.

Results at a glance

  • good tested units per shift: 595 units (headline result)
  • gross end-of-line test capacity: 620 units
  • tested units lost to station downtime: 6.2 units
  • tested units lost to test or inspection rejects: 18.41 units

Run it with your numbers

  • Every input above is editable in the live End-of-Line Test Throughput calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.