Industrial Packaging Materials Manufacturing worked example

Roll Diameter Capacity at 98% expected line uptime: a worked example

Push expected line uptime up to 98% and the picture changes. This example computes every intermediate figure at that operating point. Use this when verifying that a rewinder, slitter, or converting line has enough capacity to meet a customer order, or when comparing shift output across different roll specs.

The inputs for this scenario

  • Footage produced per machine cycle: 3.5 ft / cycle (unchanged)
  • Available cycles per shift: 600 cycles (unchanged)
  • Expected line uptime: 98 % (raised for this scenario; the documented default is 85)
  • First-pass yield: 97 % (unchanged)

Working through the calculation

  • Applying the documented formula (Gross capacity = output per machine cycle x available cycles per shift) to the inputs above produces each figure below.
  • At this operating point the engine returns 1,996 units for net good footage per shift, the number this scenario is built around.
  • At this operating point the engine returns 2,100 units for gross footage capacity.
  • At this operating point the engine returns 42 units for downtime loss (footage).
  • At this operating point the engine returns 61.74 units for yield loss (footage).

How this compares with the baseline

  • Against the tool's baseline example, where expected line uptime sits at 85% and the headline result is 1,731 units, this scenario comes in 15.29% above the baseline at 1,996 units.
  • It computes net good footage per shift by taking gross cycle output and discounting it for line uptime and first-pass yield, while breaking out downtime and yield losses separately. The value of this scenario is the size of the gap it exposes: that gap, priced out over a year, is the budget you can justify spending to close it.

Results at a glance

  • Net good footage per shift: 1,996 units (headline result)
  • Gross footage capacity: 2,100 units
  • Downtime loss (footage): 42 units
  • Yield loss (footage): 61.74 units

Run it with your numbers

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

Last reviewed 2026-05-12.