Gypsum, Drywall & Interior Panel Manufacturing worked example

Stacker Capacity at 65% stacker uptime: a worked example

This worked example runs the stacker capacity numbers for a tougher week than the baseline: 65% stacker uptime instead of the typical 90%. Estimate end-of-line stacker output for a shift by combining boards per stack, stacks per shift, stacker uptime, and quality yield.

The inputs for this scenario

  • Boards per stack: 4 boards / stack (held at the documented default)
  • Stacks per shift: 480 stacks / shift (held at the documented default)
  • Stacker uptime: 65 % (the input this scenario stresses; the baseline uses 90)
  • Quality yield: 97 % (held at the documented default)

Working through the calculation

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

How this compares with the baseline

  • Against the tool's baseline example, where stacker uptime sits at 90% and the headline result is 1,676 boards, this scenario comes in 27.78% below the baseline at 1,211 boards.
  • Use it when planning shift targets, validating a stacker rate against dryer output, or quantifying how much capacity uptime and reject losses are costing you. 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: 1,211 boards (headline result)
  • Gross capacity: 1,920 boards
  • Uptime loss: 672 boards
  • Yield loss: 37.44 boards

Run it with your numbers

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

Last reviewed 2026-05-12.