Hydrogen Electrolyzer & Fuel Cell Manufacturing worked example

Clean Assembly Labor at 25% gowning, esd, and end-plate torque allowance: a worked example in hydrogen electrolyzer & fuel cell manufacturing

This worked example runs the clean assembly labor numbers for a tougher week than the baseline: 25% gowning, esd, and end-plate torque allowance instead of the typical 35%. Estimate clean stack assembly labor per stack from cells per stack, the per-cell stack-up rate (cells stacked, aligned, and sealed per minute), and an allowance for gowning, ESD, end-plate torque, and clean room transitions.

The inputs for this scenario

  • Cells per stack to assemble: 100 cells (held at the documented default)
  • Per-cell stack-up rate: 2.5 cells / min (held at the documented default)
  • Gowning, ESD, and end-plate torque allowance: 25 % (the input this scenario stresses; the baseline uses 35)

Working through the calculation

  • The calculation starts from the formula this tool documents: Base clean assembly labor = cells per stack รท stack-up rate.
  • Required clean assembly labor per stack works out to 50 hr at these inputs, and this is the headline figure for the scenario.
  • Base clean assembly labor per stack works out to 40 hr at these inputs.
  • Gowning, ESD, and torque allowance works out to 25 % at these inputs.
  • Per-cell stack-up rate works out to 2.5 pieces / min at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where gowning, esd, and end-plate torque allowance sits at 35% and the headline result is 54 hr, this scenario comes in 7.41% below the baseline at 50 hr.
  • Use it when planning headcount and takt for a new stack line, quoting build labor, or comparing the labor impact of higher cell counts versus faster stack-up tooling. 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

  • Required clean assembly labor per stack: 50 hr (headline result)
  • Base clean assembly labor per stack: 40 hr
  • Gowning, ESD, and torque allowance: 25 %
  • Per-cell stack-up rate: 2.5 pieces / min

Run it with your numbers

  • To rerun this with your own numbers, open the live Clean Assembly Labor calculator, set gowning, esd, and end-plate torque allowance to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.