Forklifts, Lift Equipment & Material Handling Vehicles worked example

Throughput Gap with actual achievable throughput of 45 units / hr: a worked example in forklifts, lift equipment & material handling vehicles

What does the result look like when actual achievable throughput reaches 45 units / hr? The full calculation is worked below with real intermediate numbers. Use it when forklift builds, pallet moves, service jobs, charger installs, test stands, paint lines, or dealer-prep bays must meet a schedule or customer demand rate.

The inputs for this scenario

  • Actual achievable throughput: 45 units / hr (raised for this scenario; the documented default is 18)
  • Required throughput to hit plan: 22 units / hr (unchanged)
  • Reference rate for percentage: 22 units / hr (unchanged)

Working through the calculation

  • Applying the documented formula (Throughput Gap gap = available throughput - required throughput) to the inputs above produces each figure below.
  • At this operating point the engine returns 23 units / hr for throughput gap gap, the number this scenario is built around.
  • At this operating point the engine returns 105 % for throughput gap margin.
  • At this operating point the engine returns 45 value for available throughput.
  • At this operating point the engine returns 22 value for required throughput.

How this compares with the baseline

  • Against the tool's baseline example, where actual achievable throughput sits at 18 units / hr and the headline result is -4 units / hr, this scenario comes in 675% above the baseline at 23 units / hr.
  • A figure at this level is achievable when actual achievable throughput is genuinely sustained, not just peaked for a shift. It assumes a steady-state hourly rate and ignores changeovers, micro-stops, and ramp-up that erode real output further.

Results at a glance

  • Throughput Gap gap: 23 units / hr (headline result)
  • Throughput Gap margin: 105 %
  • Available throughput: 45 value
  • Required throughput: 22 value

Run it with your numbers

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

Last reviewed 2026-05-12.