Heat Exchanger, Coil & Radiator Manufacturing worked example

Leak Test Capacity at 65% leak test station uptime: a worked example in heat exchanger, coil & radiator manufacturing

Here is what the math looks like when conditions slip. We hold every other input steady and drop leak test station uptime to 65%, then walk the calculation through step by step. Estimate good leak-tested heat exchanger assemblies per shift from test fixtures, cycles, station uptime, and first-pass leak test yield.

The inputs for this scenario

  • Assemblies leak-tested per pressure-decay cycle: 4 assemblies / cycle (held at the documented default)
  • Usable leak test cycles per shift: 48 cycles / shift (held at the documented default)
  • Leak test station uptime: 65 % (the input this scenario stresses; the baseline uses 90)
  • First-pass leak test yield: 97 % (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Gross leak test capacity = assemblies tested per cycle × usable leak test cycles.
  • Good leak-tested output works out to 121 assemblies / shift at these inputs, and this is the headline figure for the scenario.
  • Gross leak test capacity works out to 192 assemblies / shift at these inputs.
  • Station downtime loss works out to 67.2 assemblies / shift at these inputs.
  • Leak reject loss works out to 3.74 assemblies / shift at these inputs.

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 27.78% below the baseline at 121 assemblies / shift.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to leak test station uptime, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. It assumes a steady cycle time and a single stable yield; real shifts mix product families with different fill, dwell and evacuation times, so validate the cycles-per-shift input against actual booth logs.

Results at a glance

  • Good leak-tested output: 121 assemblies / shift (headline result)
  • Gross leak test capacity: 192 assemblies / shift
  • Station downtime loss: 67.2 assemblies / shift
  • Leak reject loss: 3.74 assemblies / shift

Run it with your numbers

  • To rerun this with your own numbers, open the live Leak Test Capacity calculator, set leak test station uptime to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.