Consumer Goods & Durable Products Manufacturing worked example

End-of-Line Test Throughput at 63% test station uptime: a worked example

Suppose test station uptime falls to 63%. This page works the full calculation at that level so you can see exactly which result moves and by how much. Estimate good tested-unit capacity at end-of-line inspection or functional test.

The inputs for this scenario

  • Units completed per test cycle: 4 units / cycle (held at the documented default)
  • Planned end-of-line test cycles per shift: 155 cycles (held at the documented default)
  • Test station uptime: 63 % (the input this scenario stresses; the baseline uses 88)
  • End-of-line first-pass yield: 97 % (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Gross end-of-line test capacity = units completed per test cycle × planned end-of-line test cycles.
  • good tested units per shift works out to 379 units at these inputs, and this is the headline figure for the scenario.
  • gross end-of-line test capacity works out to 620 units at these inputs.
  • tested units lost to station downtime works out to 229 units at these inputs.
  • tested units lost to test or inspection rejects works out to 11.72 units at these inputs.

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 28.41% below the baseline at 379 units.
  • It computes good tested units per shift as units-per-cycle times planned cycles, then derated by station uptime and first-pass yield. When the numbers land here, the stressed input is the lever to work; the walkthrough above shows exactly how much each output recovers as it climbs back toward the baseline.

Results at a glance

  • good tested units per shift: 379 units (headline result)
  • gross end-of-line test capacity: 620 units
  • tested units lost to station downtime: 229 units
  • tested units lost to test or inspection rejects: 11.72 units

Run it with your numbers

  • To rerun this with your own numbers, open the live End-of-Line Test Throughput calculator, set test station uptime to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.