Fire Suppression, Sprinkler & Safety System Products worked example

Packaging Count at 99% packaging station uptime: a worked example in fire suppression, sprinkler & safety system products

What does the result look like when packaging station uptime reaches 99%? The full calculation is worked below with real intermediate numbers. Use it when planning packaging for sprinkler heads, valves, cylinders, extinguishers, alarm devices, detectors, signage, or safety-system kits.

The inputs for this scenario

  • Sprinkler heads packaged per cycle: 24 products / cycle (unchanged)
  • Available packaging cycles per shift: 60 cycles (unchanged)
  • Packaging station uptime: 99 % (raised for this scenario; the documented default is 90)
  • Accepted pack-out yield: 98 % (unchanged)

Working through the calculation

  • Applying the documented formula (Gross packaging count = products packaged per cycle × available packaging cycles) to the inputs above produces each figure below.
  • At this operating point the engine returns 1,397 units for good output capacity, the number this scenario is built around.
  • At this operating point the engine returns 1,440 units for gross capacity before uptime and yield.
  • At this operating point the engine returns 14.4 units for availability loss.
  • At this operating point the engine returns 28.51 units for reject or rework allowance.

How this compares with the baseline

  • Against the tool's baseline example, where packaging station uptime sits at 90% and the headline result is 1,270 units, this scenario comes in 10% above the baseline at 1,397 units.
  • A figure at this level is achievable when packaging station uptime is genuinely sustained, not just peaked for a shift. It assumes uptime and yield hold steady across the shift; a single jammed labeler or a bad carton lot can pull real output well below the modeled good capacity.

Results at a glance

  • Good output capacity: 1,397 units (headline result)
  • Gross capacity before uptime and yield: 1,440 units
  • Availability loss: 14.4 units
  • Reject or rework allowance: 28.51 units

Run it with your numbers

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

Last reviewed 2026-05-12.