Planning worked example

Capacity Planning at 61% expected uptime: a worked example

This worked example runs the capacity planning numbers for a tougher week than the baseline: 61% expected uptime instead of the typical 85%. Check whether a line can meet demand with current cycle time, uptime, shifts, and yield.

The inputs for this scenario

  • Cycle time: 40 sec / unit (held at the documented default)
  • Expected uptime: 61 % (the input this scenario stresses; the baseline uses 85)
  • Shift length: 8 hr (held at the documented default)
  • Shifts per day: 2 shifts (held at the documented default)
  • Machines / lines: 1 count (held at the documented default)
  • Good yield: 96 % (held at the documented default)
  • Daily demand: 1,150 units (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Capacity = rate × hours × shifts × machines × uptime × yield.
  • Daily capacity works out to 843 good units / day at these inputs, and this is the headline figure for the scenario.
  • Demand gap works out to -307 units / day at these inputs.
  • Required machines works out to 1.36 machines at these inputs.
  • Capacity per machine works out to 843 units / day at these inputs.

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 28.24% below the baseline at 843 good units / day.
  • Use it when evaluating whether to take an order, add a shift, or buy equipment, and during S&OP to check that capacity covers the forecast. 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

  • Daily capacity: 843 good units / day (headline result)
  • Demand gap: -307 units / day
  • Required machines: 1.36 machines
  • Capacity per machine: 843 units / day

Run it with your numbers

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

Last reviewed 2026-05-12.