Conveyors worked example

Rework Loop Capacity at 99% rework loop uptime: a worked example

Push rework loop uptime up to 99% and the picture changes. This example computes every intermediate figure at that operating point. a quality or production engineer needs to know whether the rework loop can absorb expected defects

The inputs for this scenario

  • Active rework positions: 2 positions (unchanged)
  • Rework cycles per position-hour: 85 cycles / position-hr (unchanged)
  • Rework loop uptime: 99 % (raised for this scenario; the documented default is 88)
  • Successful rework recovery yield: 72 % (unchanged)

Working through the calculation

  • Applying the documented formula (Gross rework attempts = rework positions × cycles per position-hour) to the inputs above produces each figure below.
  • At this operating point the engine returns 121 good units / hr for recovered good units, the number this scenario is built around.
  • At this operating point the engine returns 170 units / hr for gross rework attempts.
  • At this operating point the engine returns 1.7 units / hr for attempts lost to rework downtime.
  • At this operating point the engine returns 47.12 units / hr for attempts not recovered.

How this compares with the baseline

  • Against the tool's baseline example, where rework loop uptime sits at 88% and the headline result is 108 good units / hr, this scenario comes in 12.5% above the baseline at 121 good units / hr.
  • It computes recovered good units per hour from rework positions times cycles per position-hour, derated by loop uptime and recovery 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

  • Recovered good units: 121 good units / hr (headline result)
  • Gross rework attempts: 170 units / hr
  • Attempts lost to rework downtime: 1.7 units / hr
  • Attempts not recovered: 47.12 units / hr

Run it with your numbers

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

Last reviewed 2026-05-12.