Heat Exchanger, Coil & Radiator Manufacturing worked example

Leak Test Capacity at 99% leak test station uptime: a worked example in heat exchanger, coil & radiator manufacturing

This scenario runs the leak test capacity calculation on the strong side: 99% leak test station uptime, with every other input held at its documented default. Use it when helium, air decay, pressure decay, dunk, or mass spectrometer leak testing limits coil, radiator, condenser, or oil cooler shipments.

The inputs for this scenario

  • Assemblies leak-tested per pressure-decay cycle: 4 assemblies / cycle (unchanged)
  • Usable leak test cycles per shift: 48 cycles / shift (unchanged)
  • Leak test station uptime: 99 % (raised for this scenario; the documented default is 90)
  • First-pass leak test yield: 97 % (unchanged)

Working through the calculation

  • Applying the documented formula (Gross leak test capacity = assemblies tested per cycle × usable leak test cycles) to the inputs above produces each figure below.
  • At this operating point the engine returns 184 assemblies / shift for good leak-tested output, the number this scenario is built around.
  • At this operating point the engine returns 192 assemblies / shift for gross leak test capacity.
  • At this operating point the engine returns 1.92 assemblies / shift for station downtime loss.
  • At this operating point the engine returns 5.7 assemblies / shift for leak reject loss.

How this compares with the baseline

  • Against the tool's baseline example, where leak test station uptime sits at 90% and the headline result is 168 assemblies / shift, this scenario comes in 10% above the baseline at 184 assemblies / shift.
  • Use it when planning shift output, sizing the leak test booth against upstream braze or fin-pack rates, or building a business case for additional test fixtures. Treat this as a target state: the delta against the baseline quantifies what the improvement is worth before you commit to chasing it.

Results at a glance

  • Good leak-tested output: 184 assemblies / shift (headline result)
  • Gross leak test capacity: 192 assemblies / shift
  • Station downtime loss: 1.92 assemblies / shift
  • Leak reject loss: 5.7 assemblies / shift

Run it with your numbers

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

Last reviewed 2026-05-12.