MES, MOM & Shop-Floor Data Systems worked example

Digital Dispatch Adherence at 99% expected line availability: a worked example

What does the result look like when expected line availability reaches 99%? The full calculation is worked below with real intermediate numbers. Use when setting realistic shift output targets for digitally-dispatched work orders. Shows the difference between theoretical gross capacity and actual good units after availability and yield losses.

The inputs for this scenario

  • Planned good units per dispatch cycle: 50 units / cycle (unchanged)
  • Dispatch cycles released per shift: 8 cycles / shift (unchanged)
  • Expected line availability: 99 % (raised for this scenario; the documented default is 88)
  • Expected first-pass yield: 95 % (unchanged)

Working through the calculation

  • Applying the documented formula (Gross shift capacity = units per cycle x dispatch cycles per shift) to the inputs above produces each figure below.
  • At this operating point the engine returns 376 units for good units per shift, the number this scenario is built around.
  • At this operating point the engine returns 400 units for gross shift capacity.
  • At this operating point the engine returns 4 units for availability loss.
  • At this operating point the engine returns 19.8 units for first-pass yield loss.

How this compares with the baseline

  • Against the tool's baseline example, where expected line availability sits at 88% and the headline result is 334 units, this scenario comes in 12.5% above the baseline at 376 units.
  • A figure at this level is achievable when expected line availability is genuinely sustained, not just peaked for a shift. It treats availability and yield as single shift-level percentages, so mixed product runs or mid-shift changeovers with different rates need separate calculations.

Results at a glance

  • Good units per shift: 376 units (headline result)
  • Gross shift capacity: 400 units
  • Availability loss: 4 units
  • First-pass yield loss: 19.8 units

Run it with your numbers

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

Last reviewed 2026-05-12.