Doors, Hardware & Access Control Manufacturing worked example

Lockset Assembly Throughput at 65% lock assembly line availability: a worked example

Here is what the math looks like when conditions slip. We hold every other input steady and drop lock assembly line availability to 65%, then walk the calculation through step by step. Estimate good lockset, latch, cylinder, or electronic lock assemblies available per shift after line availability and functional-test yield.

The inputs for this scenario

  • Finished locksets per assembly cycle: 4 locksets / cycle (held at the documented default)
  • Scheduled lock assembly cycles: 480 cycles / shift (held at the documented default)
  • Lock assembly line availability: 65 % (the input this scenario stresses; the baseline uses 90)
  • First-pass lock functional yield: 97 % (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Gross lockset assembly capacity = finished locksets per assembly cycle × scheduled lock assembly cycles.
  • Good locksets available works out to 1,211 locksets / shift at these inputs, and this is the headline figure for the scenario.
  • Gross lockset assembly capacity works out to 1,920 locksets / shift at these inputs.
  • Lock assembly availability loss works out to 672 locksets / shift at these inputs.
  • Functional-test yield loss works out to 37.44 locksets / shift at these inputs.

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 27.78% below the baseline at 1,211 locksets / shift.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to lock assembly line availability, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. 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: 1,211 locksets / shift (headline result)
  • Gross lockset assembly capacity: 1,920 locksets / shift
  • Lock assembly availability loss: 672 locksets / shift
  • Functional-test yield loss: 37.44 locksets / shift

Run it with your numbers

  • To rerun this with your own numbers, open the live Lockset Assembly Throughput calculator, set lock assembly line availability to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.