Nonwoven Materials & Technical Textiles worked example

Capacity Gap at 65% expected line uptime: a worked example in nonwoven materials & technical textiles

This worked example runs the capacity gap numbers for a tougher week than the baseline: 65% expected line uptime instead of the typical 90%. Estimate capacity gap for nonwoven materials and technical textiles using production-ready inputs so teams can confirm whether capacity can cover demand before committing the schedule.

The inputs for this scenario

  • Good web output per machine cycle: 4 units / cycle (held at the documented default)
  • Available production cycles in window: 480 cycles (held at the documented default)
  • Expected line uptime: 65 % (the input this scenario stresses; the baseline uses 90)
  • Expected first-pass yield: 97 % (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Gross capacity gap capacity = capacity gap output per cycle × available capacity gap cycles.
  • Good capacity gap capacity works out to 1,211 units at these inputs, and this is the headline figure for the scenario.
  • Gross capacity gap capacity works out to 1,920 units at these inputs.
  • Capacity gap downtime loss works out to 672 units at these inputs.
  • Capacity gap yield loss works out to 37.44 units at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where expected line uptime sits at 90% and the headline result is 1,676 units, this scenario comes in 27.78% below the baseline at 1,211 units.
  • Use it when quoting a new run, validating a production plan against demand, or building the business case for an uptime or yield improvement project. 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 capacity gap capacity: 1,211 units (headline result)
  • Gross capacity gap capacity: 1,920 units
  • Capacity gap downtime loss: 672 units
  • Capacity gap yield loss: 37.44 units

Run it with your numbers

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

Last reviewed 2026-05-12.