Conveyors worked example

Shift Capacity at 99% expected shift uptime: a worked example

This scenario runs the shift capacity calculation on the strong side: 99% expected shift uptime, with every other input held at its documented default. a production planner needs to commit a shift quantity using actual uptime and first-pass yield

The inputs for this scenario

  • Units completed each line cycle: 1 units / cycle (unchanged)
  • Planned line cycles per shift: 1,450 cycles / shift (unchanged)
  • Expected shift uptime: 99 % (raised for this scenario; the documented default is 88)
  • Expected first-pass yield: 97 % (unchanged)

Working through the calculation

  • Applying the documented formula (Gross shift capacity = units per cycle × planned line cycles) to the inputs above produces each figure below.
  • At this operating point the engine returns 1,392 good units / shift for good shift capacity, the number this scenario is built around.
  • At this operating point the engine returns 1,450 units / shift for gross shift capacity.
  • At this operating point the engine returns 14.5 units / shift for units lost to downtime.
  • At this operating point the engine returns 43.07 units / shift for units lost to rejects.

How this compares with the baseline

  • Against the tool's baseline example, where expected shift uptime sits at 88% and the headline result is 1,238 good units / shift, this scenario comes in 12.5% above the baseline at 1,392 good units / shift.
  • Use it when committing shift output to a schedule, sizing crews, or quantifying the gap between theoretical and demonstrated capacity. 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

  • Good shift capacity: 1,392 good units / shift (headline result)
  • Gross shift capacity: 1,450 units / shift
  • Units lost to downtime: 14.5 units / shift
  • Units lost to rejects: 43.07 units / shift

Run it with your numbers

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

Last reviewed 2026-05-12.