MES, MOM & Shop-Floor Data Systems worked example

Shop-Floor Data Capture Coverage at 68% target capture rate: a worked example

Suppose target capture rate falls to 68%. This page works the full calculation at that level so you can see exactly which result moves and by how much. Measure what percentage of required production data points are captured digitally via PLCs, sensors, or barcode scans, and how far you are from your target coverage.

The inputs for this scenario

  • Data points captured automatically: 187 points (held at the documented default)
  • Total required data points per shift: 240 points (held at the documented default)
  • Target capture rate: 68 % (the input this scenario stresses; the baseline uses 95)

Working through the calculation

  • The calculation starts from the formula this tool documents: Capture rate = (data points captured automatically / total required data points) x 100.
  • Data capture coverage rate works out to 77.92 % at these inputs, and this is the headline figure for the scenario.
  • Gap to target capture rate works out to -9.92 points at these inputs.
  • Data points captured automatically works out to 187 count at these inputs.
  • Total required data points works out to 240 count at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where target capture rate sits at 95% and the headline result is 77.92 %, this scenario lands almost exactly on the baseline at 77.92 %.
  • It computes the percentage of required data points captured automatically and the gap in percentage points between that rate and your target. When the numbers land here, the stressed input is the lever to work; the walkthrough above shows exactly how much each output recovers as it climbs back toward the baseline.

Results at a glance

  • Data capture coverage rate: 77.92 % (headline result)
  • Gap to target capture rate: -9.92 points
  • Data points captured automatically: 187 count
  • Total required data points: 240 count

Run it with your numbers

  • To rerun this with your own numbers, open the live Shop-Floor Data Capture Coverage calculator, set target capture rate to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.