Fire Suppression, Sprinkler & Safety System Products worked example

Packaging Count at 65% packaging station uptime: a worked example in fire suppression, sprinkler & safety system products

This worked example runs the packaging count numbers for a tougher week than the baseline: 65% packaging station uptime instead of the typical 90%. Estimate good packaged fire protection product output from units per pack cycle, available cycles, packaging uptime, and accepted pack-out yield.

The inputs for this scenario

  • Sprinkler heads packaged per cycle: 24 products / cycle (held at the documented default)
  • Available packaging cycles per shift: 60 cycles (held at the documented default)
  • Packaging station uptime: 65 % (the input this scenario stresses; the baseline uses 90)
  • Accepted pack-out yield: 98 % (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Gross packaging count = products packaged per cycle × available packaging cycles.
  • Good output capacity works out to 917 units at these inputs, and this is the headline figure for the scenario.
  • Gross capacity before uptime and yield works out to 1,440 units at these inputs.
  • Availability loss works out to 504 units at these inputs.
  • Reject or rework allowance works out to 18.72 units at these inputs.

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 27.78% below the baseline at 917 units.
  • Use it when committing a shift or daily packaging volume for fire protection SKUs, sizing labor against a backlog, or validating whether a line can clear a UL-lotted order on time. 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

  • Good output capacity: 917 units (headline result)
  • Gross capacity before uptime and yield: 1,440 units
  • Availability loss: 504 units
  • Reject or rework allowance: 18.72 units

Run it with your numbers

  • To rerun this with your own numbers, open the live Packaging Count calculator, set packaging station uptime to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.