Metals, Steel, Aluminum & Coil Processing worked example

Flattening Line Capacity at 99% leveling line uptime: a worked example

What does the result look like when leveling line uptime reaches 99%? The full calculation is worked below with real intermediate numbers. Use it when a cut-to-length or leveling line supervisor needs the realistic good sheet count per shift after downtime and leveling rejects.

The inputs for this scenario

  • Sheets produced per leveling cycle: 20 sheets / cycle (unchanged)
  • Available leveling cycles: 480 cycles (unchanged)
  • Leveling line uptime: 99 % (raised for this scenario; the documented default is 90)
  • Yield of flat sheets after leveling: 97 % (unchanged)

Working through the calculation

  • Applying the documented formula (Gross sheets capacity = sheets per cycle × available cycles) to the inputs above produces each figure below.
  • At this operating point the engine returns 9,219 sheets for good sheets capacity, the number this scenario is built around.
  • At this operating point the engine returns 9,600 sheets for gross sheets capacity.
  • At this operating point the engine returns 96 sheets for uptime loss.
  • At this operating point the engine returns 285 sheets for leveling yield loss.

How this compares with the baseline

  • Against the tool's baseline example, where leveling line uptime sits at 90% and the headline result is 8,381 sheets, this scenario comes in 10% above the baseline at 9,219 sheets.
  • A figure at this level is achievable when leveling line uptime is genuinely sustained, not just peaked for a shift. It assumes a constant sheets-per-cycle and uniform yield; gauge changes, recoil stops, or varying flatness specs across orders will shift the real number.

Results at a glance

  • Good sheets capacity: 9,219 sheets (headline result)
  • Gross sheets capacity: 9,600 sheets
  • Uptime loss: 96 sheets
  • Leveling yield loss: 285 sheets

Run it with your numbers

  • Every input above is editable in the live Flattening Line Capacity calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.