Electronics Manufacturing worked example

AOI Inspection Capacity at 99% aoi machine uptime: a worked example

Push aoi machine uptime up to 99% and the picture changes. This example computes every intermediate figure at that operating point. a quality or production engineer is checking whether AOI capacity supports SMT output

The inputs for this scenario

  • Boards inspected per AOI cycle: 1 boards / cycle (unchanged)
  • Available AOI cycles: 2,200 cycles / shift (unchanged)
  • AOI machine uptime: 99 % (raised for this scenario; the documented default is 91)
  • First-pass AOI yield: 96 % (unchanged)

Working through the calculation

  • Applying the documented formula (Gross AOI board capacity = boards inspected per AOI cycle × available AOI cycles) to the inputs above produces each figure below.
  • At this operating point the engine returns 2,091 boards / shift for usable aoi inspection capacity, the number this scenario is built around.
  • At this operating point the engine returns 2,200 boards / shift for gross aoi board capacity.
  • At this operating point the engine returns 22 boards / shift for boards lost to aoi downtime.
  • At this operating point the engine returns 87.12 boards / shift for boards held for review or defect disposition.

How this compares with the baseline

  • Against the tool's baseline example, where aoi machine uptime sits at 91% and the headline result is 1,922 boards / shift, this scenario comes in 8.79% above the baseline at 2,091 boards / shift.
  • It computes usable AOI inspection capacity in boards per shift after derating gross cycle output by machine uptime and first-pass 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

  • Usable AOI inspection capacity: 2,091 boards / shift (headline result)
  • Gross AOI board capacity: 2,200 boards / shift
  • Boards lost to AOI downtime: 22 boards / shift
  • Boards held for review or defect disposition: 87.12 boards / shift

Run it with your numbers

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

Last reviewed 2026-05-12.