Gypsum, Drywall & Interior Panel Manufacturing worked example

Packaging Count at 65% packaging uptime: a worked example in gypsum, drywall & interior panel manufacturing

Suppose packaging uptime falls to 65%. This page works the full calculation at that level so you can see exactly which result moves and by how much. Estimate board packaging output for a shift by combining boards per pallet, pallets per shift, packaging uptime, and packaging yield.

The inputs for this scenario

  • Boards per pallet: 4 boards / pallet (held at the documented default)
  • Pallets per shift: 480 pallets / shift (held at the documented default)
  • Packaging uptime: 65 % (the input this scenario stresses; the baseline uses 90)
  • Packaging yield: 97 % (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Gross packaging output = boards per pallet x pallets per shift.
  • Good output capacity works out to 1,211 pallets at these inputs, and this is the headline figure for the scenario.
  • Gross capacity works out to 1,920 pallets at these inputs.
  • Uptime loss works out to 672 pallets at these inputs.
  • Yield loss works out to 37.44 pallets at these inputs.

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 27.78% below the baseline at 1,211 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. When the numbers land here, the stressed input is the lever to work; the walkthrough above shows exactly how much each output recovers as it climbs back toward the baseline.

Results at a glance

  • Good output capacity: 1,211 pallets (headline result)
  • Gross capacity: 1,920 pallets
  • Uptime loss: 672 pallets
  • Yield loss: 37.44 pallets

Run it with your numbers

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

Last reviewed 2026-05-12.