Industrial Packaging Materials Manufacturing worked example

Roll Diameter Capacity at 61% expected line uptime: a worked example

Here is what the math looks like when conditions slip. We hold every other input steady and drop expected line uptime to 61%, then walk the calculation through step by step. Calculate the usable footage capacity of a roll based on output per revolution, available revolutions, line uptime, and first-pass yield so you can confirm production capacity before scheduling.

The inputs for this scenario

  • Footage produced per machine cycle: 3.5 ft / cycle (held at the documented default)
  • Available cycles per shift: 600 cycles (held at the documented default)
  • Expected line uptime: 61 % (the input this scenario stresses; the baseline uses 85)
  • First-pass yield: 97 % (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Gross capacity = output per machine cycle x available cycles per shift.
  • Net good footage per shift works out to 1,243 units at these inputs, and this is the headline figure for the scenario.
  • Gross footage capacity works out to 2,100 units at these inputs.
  • Downtime loss (footage) works out to 819 units at these inputs.
  • Yield loss (footage) works out to 38.43 units at these inputs.

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 28.24% below the baseline at 1,243 units.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to expected line uptime, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. Output per cycle is treated as constant, so runs with mixed roll widths, gauge changes, or speed ramps need to be modeled as separate cycles or averaged carefully.

Results at a glance

  • Net good footage per shift: 1,243 units (headline result)
  • Gross footage capacity: 2,100 units
  • Downtime loss (footage): 819 units
  • Yield loss (footage): 38.43 units

Run it with your numbers

  • To rerun this with your own numbers, open the live Roll Diameter Capacity calculator, set expected line uptime to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.