Conveyors worked example

Reject Station Capacity at 99% reject station uptime: a worked example

This scenario runs the reject station capacity calculation on the strong side: 99% reject station uptime, with every other input held at its documented default. a quality or automation engineer needs to confirm that a reject station will not become a bottleneck

The inputs for this scenario

  • Active reject handling positions: 2 positions (unchanged)
  • Reject cycles per position-hour: 180 cycles / position-hr (unchanged)
  • Reject station uptime: 99 % (raised for this scenario; the documented default is 92)
  • Successful reject disposition rate: 98 % (unchanged)

Working through the calculation

  • Applying the documented formula (Gross reject station capacity = positions × cycles per position-hour) to the inputs above produces each figure below.
  • At this operating point the engine returns 349 parts / hr for reject station capacity, the number this scenario is built around.
  • At this operating point the engine returns 360 parts / hr for gross reject handling capacity.
  • At this operating point the engine returns 3.6 parts / hr for reject capacity lost to downtime.
  • At this operating point the engine returns 7.13 parts / hr for rejects not dispositioned correctly.

How this compares with the baseline

  • Against the tool's baseline example, where reject station uptime sits at 92% and the headline result is 325 parts / hr, this scenario comes in 7.61% above the baseline at 349 parts / hr.
  • Use it when sizing a reject diverter or sortation cell, or when investigating whether a backed-up reject path is blocking the main line. 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

  • Reject station capacity: 349 parts / hr (headline result)
  • Gross reject handling capacity: 360 parts / hr
  • Reject capacity lost to downtime: 3.6 parts / hr
  • Rejects not dispositioned correctly: 7.13 parts / hr

Run it with your numbers

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

Last reviewed 2026-05-12.