Doors, Hardware & Access Control Manufacturing worked example

Lockset Assembly Throughput at 99% lock assembly line availability: a worked example

What does the result look like when lock assembly line availability reaches 99%? The full calculation is worked below with real intermediate numbers. Use it when lockset assembly throughput in doors, hardware and access control manufacturing is being asked to take on more work and you need to know if there is room.

The inputs for this scenario

  • Finished locksets per assembly cycle: 4 locksets / cycle (unchanged)
  • Scheduled lock assembly cycles: 480 cycles / shift (unchanged)
  • Lock assembly line availability: 99 % (raised for this scenario; the documented default is 90)
  • First-pass lock functional yield: 97 % (unchanged)

Working through the calculation

  • Applying the documented formula (Gross lockset assembly capacity = finished locksets per assembly cycle × scheduled lock assembly cycles) to the inputs above produces each figure below.
  • At this operating point the engine returns 1,844 locksets / shift for good locksets available, the number this scenario is built around.
  • At this operating point the engine returns 1,920 locksets / shift for gross lockset assembly capacity.
  • At this operating point the engine returns 19.2 locksets / shift for lock assembly availability loss.
  • At this operating point the engine returns 57.02 locksets / shift for functional-test yield loss.

How this compares with the baseline

  • Against the tool's baseline example, where lock assembly line availability sits at 90% and the headline result is 1,676 locksets / shift, this scenario comes in 10% above the baseline at 1,844 locksets / shift.
  • A figure at this level is achievable when lock assembly line availability is genuinely sustained, not just peaked for a shift. It models availability and yield as flat percentages over the shift; a line with a long mid-shift jam or a quality drift produces a different mix of losses than these averages imply.

Results at a glance

  • Good locksets available: 1,844 locksets / shift (headline result)
  • Gross lockset assembly capacity: 1,920 locksets / shift
  • Lock assembly availability loss: 19.2 locksets / shift
  • Functional-test yield loss: 57.02 locksets / shift

Run it with your numbers

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

Last reviewed 2026-05-12.