Planning worked example

Capacity Planning at 98% expected uptime: a worked example

What does the result look like when expected uptime reaches 98%? The full calculation is worked below with real intermediate numbers. Use before accepting demand or adding equipment.

The inputs for this scenario

  • Cycle time: 40 sec / unit (unchanged)
  • Expected uptime: 98 % (raised for this scenario; the documented default is 85)
  • Shift length: 8 hr (unchanged)
  • Shifts per day: 2 shifts (unchanged)
  • Machines / lines: 1 count (unchanged)
  • Good yield: 96 % (unchanged)
  • Daily demand: 1,150 units (unchanged)

Working through the calculation

  • Applying the documented formula (Capacity = rate × hours × shifts × machines × uptime × yield) to the inputs above produces each figure below.
  • At this operating point the engine returns 1,355 good units / day for daily capacity, the number this scenario is built around.
  • At this operating point the engine returns 205 units / day for demand gap.
  • At this operating point the engine returns 0.85 machines for required machines.
  • At this operating point the engine returns 1,355 units / day for capacity per machine.

How this compares with the baseline

  • Against the tool's baseline example, where expected uptime sits at 85% and the headline result is 1,175 good units / day, this scenario comes in 15.29% above the baseline at 1,355 good units / day.
  • A figure at this level is achievable when expected uptime is genuinely sustained, not just peaked for a shift. It assumes a single representative cycle time and steady uptime and yield; mixed-product lines, changeovers, and demand variability need a more detailed model or added buffers.

Results at a glance

  • Daily capacity: 1,355 good units / day (headline result)
  • Demand gap: 205 units / day
  • Required machines: 0.85 machines
  • Capacity per machine: 1,355 units / day

Run it with your numbers

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

Last reviewed 2026-05-12.