Conveyors worked example

Reject Station Capacity at 66% reject station uptime: a worked example

Here is what the math looks like when conditions slip. We hold every other input steady and drop reject station uptime to 66%, then walk the calculation through step by step. Estimate how many rejected parts a reject, inspection, or diversion station can process per hour.

The inputs for this scenario

  • Active reject handling positions: 2 positions (held at the documented default)
  • Reject cycles per position-hour: 180 cycles / position-hr (held at the documented default)
  • Reject station uptime: 66 % (the input this scenario stresses; the baseline uses 92)
  • Successful reject disposition rate: 98 % (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Gross reject station capacity = positions × cycles per position-hour.
  • Reject station capacity works out to 233 parts / hr at these inputs, and this is the headline figure for the scenario.
  • Gross reject handling capacity works out to 360 parts / hr at these inputs.
  • Reject capacity lost to downtime works out to 122 parts / hr at these inputs.
  • Rejects not dispositioned correctly works out to 4.75 parts / hr at these inputs.

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 28.26% below the baseline at 233 parts / hr.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to reject station uptime, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. It assumes a steady reject arrival pattern; bursty defect events can overwhelm a station whose average capacity looks adequate.

Results at a glance

  • Reject station capacity: 233 parts / hr (headline result)
  • Gross reject handling capacity: 360 parts / hr
  • Reject capacity lost to downtime: 122 parts / hr
  • Rejects not dispositioned correctly: 4.75 parts / hr

Run it with your numbers

  • To rerun this with your own numbers, open the live Reject Station Capacity calculator, set reject station uptime to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.