EV Charging Infrastructure Manufacturing worked example

Production Ramp Gap at 59% expected ramp uptime: a worked example

Here is what the math looks like when conditions slip. We hold every other input steady and drop expected ramp uptime to 59%, then walk the calculation through step by step. Estimate good charger production capacity during ramp from output per cycle, available cycles, uptime, and first-pass yield.

The inputs for this scenario

  • Chargers produced per ramp cycle: 6 chargers / cycle (held at the documented default)
  • Available ramp production cycles: 120 cycles (held at the documented default)
  • Expected ramp uptime: 59 % (the input this scenario stresses; the baseline uses 82)
  • Expected ramp first-pass yield: 88 % (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Gross ramp capacity = chargers per ramp cycle × available ramp cycles.
  • Good charger ramp capacity works out to 374 units at these inputs, and this is the headline figure for the scenario.
  • Gross charger ramp capacity works out to 720 units at these inputs.
  • Ramp capacity lost to downtime and disruption works out to 295 units at these inputs.
  • Ramp capacity lost to defects and rework works out to 50.98 units at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where expected ramp uptime sits at 82% and the headline result is 520 units, this scenario comes in 28.05% below the baseline at 374 units.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to expected ramp uptime, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. It applies single ramp-average uptime and yield figures, but both improve over a learning curve, so a flat estimate understates late-ramp output and overstates early-ramp output.

Results at a glance

  • Good charger ramp capacity: 374 units (headline result)
  • Gross charger ramp capacity: 720 units
  • Ramp capacity lost to downtime and disruption: 295 units
  • Ramp capacity lost to defects and rework: 50.98 units

Run it with your numbers

  • To rerun this with your own numbers, open the live Production Ramp Gap calculator, set expected ramp uptime to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.