Mattress, Bedding & Foam Product Assembly worked example

Foam Cut Yield at 68% yield target: a worked example

This worked example runs the foam cut yield numbers for a tougher week than the baseline: 68% yield target instead of the typical 95%. Calculate the percentage of usable foam pieces produced from a foam block or bun, accounting for trim loss and off-cuts during CNC or band-saw cutting.

The inputs for this scenario

  • Usable foam pieces produced: 230 pieces (held at the documented default)
  • Total foam pieces attempted: 250 pieces (held at the documented default)
  • Yield target: 68 % (the input this scenario stresses; the baseline uses 95)

Working through the calculation

  • The calculation starts from the formula this tool documents: Foam cut yield (%) = usable pieces ÷ total pieces attempted × 100.
  • Rate works out to 92 % at these inputs, and this is the headline figure for the scenario.
  • Gap to target works out to -24 points at these inputs.
  • Affected count works out to 230 count at these inputs.
  • Total count works out to 250 count at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where yield target sits at 95% and the headline result is 92 %, this scenario lands almost exactly on the baseline at 92 %.
  • Use it at the end of each cutting shift or run, or when auditing a new blade, foam grade, or nest layout for scrap impact. 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

  • Rate: 92 % (headline result)
  • Gap to target: -24 points
  • Affected count: 230 count
  • Total count: 250 count

Run it with your numbers

  • To rerun this with your own numbers, open the live Foam Cut Yield calculator, set yield target to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.