Mattress, Bedding & Foam Product Assembly worked example

Compression Pack Rate at 99% target compression pack rate: a worked example

What does the result look like when target compression pack rate reaches 99%? The full calculation is worked below with real intermediate numbers. Use this when tracking bed-in-a-box production schedule adherence, comparing compression machine capacity to assembly output, or evaluating capital investment in faster roll-pack equipment.

The inputs for this scenario

  • Mattresses compressed and roll-packed: 92 mattresses (unchanged)
  • Mattresses scheduled for the run: 100 mattresses (unchanged)
  • Target compression pack rate: 99 % (raised for this scenario; the documented default is 95)

Working through the calculation

  • Applying the documented formula (Actual pack rate (%) = mattresses compressed ÷ total scheduled × 100) to the inputs above produces each figure below.
  • At this operating point the engine returns 92 % for rate, the number this scenario is built around.
  • At this operating point the engine returns 7 points for gap to target.
  • At this operating point the engine returns 92 count for affected count.
  • At this operating point the engine returns 100 count for total count.

How this compares with the baseline

  • Against the tool's baseline example, where target compression pack rate sits at 95% and the headline result is 92 %, this scenario lands almost exactly on the baseline at 92 %.
  • A figure at this level is achievable when target compression pack rate is genuinely sustained, not just peaked for a shift. It treats every mattress as one unit, so it won't reflect that a king takes far longer to compress than a twin — mix shifts can distort the rate.

Results at a glance

  • Rate: 92 % (headline result)
  • Gap to target: 7 points
  • Affected count: 92 count
  • Total count: 100 count

Run it with your numbers

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

Last reviewed 2026-05-12.