Metals, Steel, Aluminum & Coil Processing worked example

Metal Surcharge Impact at 65% expected uptime: a worked example

This worked example runs the metal surcharge impact numbers for a tougher week than the baseline: 65% expected uptime instead of the typical 90%. Estimate the good tonnage a metal surcharge will apply to by combining output per production cycle, the cycles available, uptime, and first-pass yield.

The inputs for this scenario

  • Tons produced per cycle: 20 tons / cycle (held at the documented default)
  • Production cycles in the period: 40 cycles (held at the documented default)
  • Expected uptime: 65 % (the input this scenario stresses; the baseline uses 90)
  • First-pass yield: 97 % (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Gross output tons = output per cycle × production cycles.
  • Good surchargeable tons works out to 504 tons at these inputs, and this is the headline figure for the scenario.
  • Gross output tons works out to 800 tons at these inputs.
  • Downtime loss works out to 280 tons at these inputs.
  • Yield loss works out to 15.6 tons at these inputs.

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 27.78% below the baseline at 504 tons.
  • Use it when forecasting surcharge-bearing volume for a period or reconciling billed surcharge tonnage against realized good output. 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

  • Good surchargeable tons: 504 tons (headline result)
  • Gross output tons: 800 tons
  • Downtime loss: 280 tons
  • Yield loss: 15.6 tons

Run it with your numbers

  • To rerun this with your own numbers, open the live Metal Surcharge Impact calculator, set expected uptime to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.