Metals, Steel, Aluminum & Coil Processing worked example

Metal Surcharge Impact at 99% expected uptime: a worked example

Push expected uptime up to 99% and the picture changes. This example computes every intermediate figure at that operating point. Use it when a buyer or estimator needs the real surchargeable tonnage per period before pricing a metal surcharge into a contract.

The inputs for this scenario

  • Tons produced per cycle: 20 tons / cycle (unchanged)
  • Production cycles in the period: 40 cycles (unchanged)
  • Expected uptime: 99 % (raised for this scenario; the documented default is 90)
  • First-pass yield: 97 % (unchanged)

Working through the calculation

  • Applying the documented formula (Gross output tons = output per cycle × production cycles) to the inputs above produces each figure below.
  • At this operating point the engine returns 768 tons for good surchargeable tons, the number this scenario is built around.
  • At this operating point the engine returns 800 tons for gross output tons.
  • At this operating point the engine returns 8 tons for downtime loss.
  • At this operating point the engine returns 23.76 tons for yield loss.

How this compares with the baseline

  • Against the tool's baseline example, where expected uptime sits at 90% and the headline result is 698 tons, this scenario comes in 10% above the baseline at 768 tons.
  • It computes good surchargeable tons as gross output (tons per cycle × cycles) reduced by expected uptime and first-pass yield, and shows the downtime and yield losses separately. The value of this scenario is the size of the gap it exposes: that gap, priced out over a year, is the budget you can justify spending to close it.

Results at a glance

  • Good surchargeable tons: 768 tons (headline result)
  • Gross output tons: 800 tons
  • Downtime loss: 8 tons
  • Yield loss: 23.76 tons

Run it with your numbers

  • Every input above is editable in the live Metal Surcharge Impact calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.