Conveyors worked example

Rework Loop Capacity at 63% rework loop uptime: a worked example

Here is what the math looks like when conditions slip. We hold every other input steady and drop rework loop uptime to 63%, then walk the calculation through step by step. Estimate good units recovered through a rework loop from rework positions, cycles, uptime, and recovery yield.

The inputs for this scenario

  • Active rework positions: 2 positions (held at the documented default)
  • Rework cycles per position-hour: 85 cycles / position-hr (held at the documented default)
  • Rework loop uptime: 63 % (the input this scenario stresses; the baseline uses 88)
  • Successful rework recovery yield: 72 % (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Gross rework attempts = rework positions × cycles per position-hour.
  • Recovered good units works out to 77.11 good units / hr at these inputs, and this is the headline figure for the scenario.
  • Gross rework attempts works out to 170 units / hr at these inputs.
  • Attempts lost to rework downtime works out to 62.9 units / hr at these inputs.
  • Attempts not recovered works out to 29.99 units / hr at these inputs.

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 28.41% below the baseline at 77.11 good units / hr.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to rework loop uptime, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. It assumes a steady supply of reworkable defects and a fixed recovery yield; parts that fail rework twice or defects that are not repairable will make real recovery lower than calculated.

Results at a glance

  • Recovered good units: 77.11 good units / hr (headline result)
  • Gross rework attempts: 170 units / hr
  • Attempts lost to rework downtime: 62.9 units / hr
  • Attempts not recovered: 29.99 units / hr

Run it with your numbers

  • To rerun this with your own numbers, open the live Rework Loop Capacity calculator, set rework loop uptime to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.