Electronics Manufacturing worked example

AOI Inspection Capacity at 66% aoi machine uptime: a worked example

This worked example runs the aoi inspection capacity numbers for a tougher week than the baseline: 66% aoi machine uptime instead of the typical 91%. Estimate AOI inspection capacity from boards per inspection cycle, available cycles, machine uptime, and first-pass inspection yield.

The inputs for this scenario

  • Boards inspected per AOI cycle: 1 boards / cycle (held at the documented default)
  • Available AOI cycles: 2,200 cycles / shift (held at the documented default)
  • AOI machine uptime: 66 % (the input this scenario stresses; the baseline uses 91)
  • First-pass AOI yield: 96 % (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Gross AOI board capacity = boards inspected per AOI cycle × available AOI cycles.
  • Usable AOI inspection capacity works out to 1,394 boards / shift at these inputs, and this is the headline figure for the scenario.
  • Gross AOI board capacity works out to 2,200 boards / shift at these inputs.
  • Boards lost to AOI downtime works out to 748 boards / shift at these inputs.
  • Boards held for review or defect disposition works out to 58.08 boards / shift at these inputs.

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 27.47% below the baseline at 1,394 boards / shift.
  • Use it when balancing an SMT line, justifying a second AOI head, or checking whether inspection can absorb a planned production ramp. A result at this level usually justifies acting on the stressed input before touching anything else, because every other figure in the table is downstream of it.

Results at a glance

  • Usable AOI inspection capacity: 1,394 boards / shift (headline result)
  • Gross AOI board capacity: 2,200 boards / shift
  • Boards lost to AOI downtime: 748 boards / shift
  • Boards held for review or defect disposition: 58.08 boards / shift

Run it with your numbers

  • To rerun this with your own numbers, open the live AOI Inspection Capacity calculator, set aoi machine uptime to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.