Hydrogen Electrolyzer & Fuel Cell Manufacturing worked example

Leak Test Capacity at 63% leak tester uptime: a worked example in hydrogen electrolyzer & fuel cell manufacturing

This worked example runs the leak test capacity numbers for a tougher week than the baseline: 63% leak tester uptime instead of the typical 88%. Estimate good-stack throughput on the leak test cell from stacks per leak-test cycle, planned cycles in the period, leak tester uptime, and leak-test pass rate at your target test pressure.

The inputs for this scenario

  • Stacks per leak test cycle: 2 stacks / cycle (held at the documented default)
  • Planned leak test cycles in the period: 40 cycles (held at the documented default)
  • Leak tester uptime: 63 % (the input this scenario stresses; the baseline uses 88)
  • Leak test first-pass rate at the target test pressure: 95 % (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Gross leak test capacity = stacks per cycle × planned cycles.
  • Good leak-test stacks per period works out to 47.88 stacks at these inputs, and this is the headline figure for the scenario.
  • Gross leak-test stacks per period works out to 80 stacks at these inputs.
  • Leak tester downtime loss works out to 29.6 stacks at these inputs.
  • Leak-test rework loss works out to 2.52 stacks at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where leak tester uptime sits at 88% and the headline result is 66.88 stacks, this scenario comes in 28.41% below the baseline at 47.88 stacks.
  • Use it when planning leak-test capacity against build rate, justifying a second tester, or quantifying how uptime and first-pass losses erode throughput. 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 leak-test stacks per period: 47.88 stacks (headline result)
  • Gross leak-test stacks per period: 80 stacks
  • Leak tester downtime loss: 29.6 stacks
  • Leak-test rework loss: 2.52 stacks

Run it with your numbers

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

Last reviewed 2026-05-12.