HVAC Ductwork, Air Handling & Mechanical Products worked example

Air Handler Coil Capacity at 65% assembly line uptime: a worked example

Suppose assembly line 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 how many chilled water or DX coil assemblies your air handler production line can complete per shift. Accounts for coils per setup, available setups, line uptime, and first-pass assembly yield.

The inputs for this scenario

  • Coil assemblies built per setup: 4 coils / setup (held at the documented default)
  • Available setups per shift: 60 setups (held at the documented default)
  • Assembly line uptime: 65 % (the input this scenario stresses; the baseline uses 90)
  • First-pass coil assembly yield: 97 % (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Gross coil capacity = coils per setup × available setups.
  • Good output capacity works out to 151 units at these inputs, and this is the headline figure for the scenario.
  • Gross capacity works out to 240 units at these inputs.
  • Uptime loss works out to 84 units at these inputs.
  • Yield loss works out to 4.68 units at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where assembly line uptime sits at 90% and the headline result is 210 units, this scenario comes in 27.78% below the baseline at 151 units.
  • It computes deliverable coil output by taking gross capacity (coils per setup times setups) and applying line uptime and first-pass yield percentages. 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: 151 units (headline result)
  • Gross capacity: 240 units
  • Uptime loss: 84 units
  • Yield loss: 4.68 units

Run it with your numbers

  • To rerun this with your own numbers, open the live Air Handler Coil Capacity calculator, set assembly line uptime to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.