How is capacity per machine calculated?

Available machine hours per day times 3,600 seconds, divided by cycle time in seconds, then multiplied by uptime and yield. Percentages are divided by 100, so 85 percent multiplies the result by 0.85.

Why round required machines up?

Because you cannot run a fraction of a machine. The required machines row keeps the fraction so you can see how close the decision is; machines to add rounds up to the next whole machine.

Does uptime include changeovers?

Enter uptime as the share of planned hours the machine can run, with planned changeovers already removed. Unplanned stoppages and breakdowns stay in the availability loss, so do not subtract them twice.

What does a negative demand gap mean?

That demand is above daily capacity. The shortfall is the negative gap, and machines to add shows the whole machines that would cover it at this cycle time, uptime and yield.

Planning calculator

Capacity Planning Calculator

Check whether the machines on hand can meet daily demand at their cycle time, uptime and yield. The rows show capacity per machine, the daily gap and the whole machines to add.

What this calculator does

Daily good-unit capacity and the gap to demand, with the whole machines to add when capacity falls short.

Formula used

Capacity per machine = available machine hours per day × 3,600 ÷ cycle time × uptime % ÷ 100 × yield % ÷ 100
Daily capacity = capacity per machine × machine count
Demand gap = daily capacity − daily demand
Required machines = daily demand ÷ capacity per machine
Machines to add = MAX(0, CEILING(required machines) − machine count)

Inputs explained

Cycle Time per Unit: Constraint time per unit from the routing or time study.
Expected Uptime: Share of planned machine hours the line is available to run.
Available Machine Hours per Day: Planned running hours per day across all shifts.
Machines or Lines: Identical machines or lines running the same cycle.
Good Yield: Good units as a share of units started, from quality logs.
Daily Demand: Units the daily schedule requires, from the demand plan.

How to use the result

Best suited to sizing a new order against the line, deciding whether to add a shift, checking capacity before a launch.
Changeovers and breaks are inside the uptime figure; do not subtract them again. Averages hide mix: one slow part in the schedule can sink the day.

Current U.S. benchmarks

U.S. manufacturing runs at 75.7% of capacity (Federal Reserve, Aug 2026). New factory orders are up 8.5% year over year (Census).

Common questions

How is capacity per machine calculated? Available machine hours per day times 3,600 seconds, divided by cycle time in seconds, then multiplied by uptime and yield. Percentages are divided by 100, so 85 percent multiplies the result by 0.85.
Why round required machines up? Because you cannot run a fraction of a machine. The required machines row keeps the fraction so you can see how close the decision is; machines to add rounds up to the next whole machine.
Does uptime include changeovers? Enter uptime as the share of planned hours the machine can run, with planned changeovers already removed. Unplanned stoppages and breakdowns stay in the availability loss, so do not subtract them twice.
What does a negative demand gap mean? That demand is above daily capacity. The shortfall is the negative gap, and machines to add shows the whole machines that would cover it at this cycle time, uptime and yield.

Related guides

Last reviewed 2026-10-01.