Conveyors worked example

Buffer Size at 99% buffer availability: a worked example

This scenario runs the buffer size calculation on the strong side: 99% buffer availability, with every other input held at its documented default. a line designer needs to size the queue between an upstream machine and a downstream constraint

The inputs for this scenario

  • Physical buffer slots available: 120 slots (unchanged)
  • Expected buffer turns per shift: 4 turns / shift (unchanged)
  • Buffer availability: 99 % (raised for this scenario; the documented default is 95)
  • Good parts released from buffer: 99 % (unchanged)

Working through the calculation

  • Applying the documented formula (Gross buffered quantity = buffer slots × buffer turns) to the inputs above produces each figure below.
  • At this operating point the engine returns 470 parts for usable buffer quantity, the number this scenario is built around.
  • At this operating point the engine returns 480 parts for gross buffer movement.
  • At this operating point the engine returns 4.8 parts for slots lost to unavailability.
  • At this operating point the engine returns 4.75 parts for parts lost during release.

How this compares with the baseline

  • Against the tool's baseline example, where buffer availability sits at 95% and the headline result is 451 parts, this scenario comes in 4.21% above the baseline at 470 parts.
  • Use it when sizing accumulation between two stations, validating that a buffer decouples them for a target downtime, or auditing why a buffer underperforms its nameplate. 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 buffer quantity: 470 parts (headline result)
  • Gross buffer movement: 480 parts
  • Slots lost to unavailability: 4.8 parts
  • Parts lost during release: 4.75 parts

Run it with your numbers

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

Last reviewed 2026-05-12.