Gypsum, Drywall & Interior Panel Manufacturing worked example

Packaging Count at 99% packaging uptime: a worked example in gypsum, drywall & interior panel manufacturing

Push packaging uptime up to 99% and the picture changes. This example computes every intermediate figure at that operating point. Use it when planning a shipping schedule and you need to confirm the packaging line can meet the pallet count commitment before the dock window closes.

The inputs for this scenario

  • Boards per pallet: 4 boards / pallet (unchanged)
  • Pallets per shift: 480 pallets / shift (unchanged)
  • Packaging uptime: 99 % (raised for this scenario; the documented default is 90)
  • Packaging yield: 97 % (unchanged)

Working through the calculation

  • Applying the documented formula (Gross packaging output = boards per pallet x pallets per shift) to the inputs above produces each figure below.
  • At this operating point the engine returns 1,844 pallets for good output capacity, the number this scenario is built around.
  • At this operating point the engine returns 1,920 pallets for gross capacity.
  • At this operating point the engine returns 19.2 pallets for uptime loss.
  • At this operating point the engine returns 57.02 pallets for yield loss.

How this compares with the baseline

  • Against the tool's baseline example, where packaging uptime sits at 90% and the headline result is 1,676 pallets, this scenario comes in 10% above the baseline at 1,844 pallets.
  • It computes good packaged units per shift by multiplying boards per pallet and pallets per shift, then derating by packaging uptime and packaging yield. The value of this scenario is the size of the gap it exposes: that gap, priced out over a year, is the budget you can justify spending to close it.

Results at a glance

  • Good output capacity: 1,844 pallets (headline result)
  • Gross capacity: 1,920 pallets
  • Uptime loss: 19.2 pallets
  • Yield loss: 57.02 pallets

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.