Fastener Manufacturing & Thread Rolling worked example

Sort Machine Output at 59% sorter efficiency after stops: a worked example

Here is what the math looks like when conditions slip. We hold every other input steady and drop sorter efficiency after stops to 59%, then walk the calculation through step by step. Estimate effective optical or mechanical fastener sorting output from accepted pieces, run hours, and sorter efficiency.

The inputs for this scenario

  • Accepted sorted fasteners: 60,000 pieces (held at the documented default)
  • Actual sorter run time: 8 hr (held at the documented default)
  • Sorter efficiency after stops: 59 % (the input this scenario stresses; the baseline uses 82)

Working through the calculation

  • The calculation starts from the formula this tool documents: Raw sorting rate = accepted sorted fasteners รท actual sorter run time.
  • Effective sorter output works out to 4,425 units / hr at these inputs, and this is the headline figure for the scenario.
  • Raw sorting rate works out to 7,500 units / hr at these inputs.
  • Sorter efficiency works out to 59 % at these inputs.
  • Sorter run time works out to 8 hr at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where sorter efficiency after stops sits at 82% and the headline result is 6,150 units / hr, this scenario comes in 28.05% below the baseline at 4,425 units / hr.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to sorter efficiency after stops, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. It is a shift-average rate; it does not capture how the rate falls for tiny or tangled parts, mixed lots, or a sorter set up for very tight reject criteria.

Results at a glance

  • Effective sorter output: 4,425 units / hr (headline result)
  • Raw sorting rate: 7,500 units / hr
  • Sorter efficiency: 59 %
  • Sorter run time: 8 hr

Run it with your numbers

  • To rerun this with your own numbers, open the live Sort Machine Output calculator, set sorter efficiency after stops to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.