NPI, DFM/DFA & Engineering Change worked example

Design Transfer Readiness at 99% expected line uptime during transfer: a worked example

Push expected line uptime during transfer up to 99% and the picture changes. This example computes every intermediate figure at that operating point. Use it when design transfer readiness in npi, dfm/dfa and engineering change is being asked to take on more work and you need to know if there is room.

The inputs for this scenario

  • Pilot-build output per transfer cycle: 4 units / cycle (unchanged)
  • Available design transfer cycles: 480 cycles (unchanged)
  • Expected line uptime during transfer: 99 % (raised for this scenario; the documented default is 90)
  • Expected first-pass yield at transfer: 97 % (unchanged)

Working through the calculation

  • Applying the documented formula (Gross design transfer readiness capacity = design transfer readiness output per cycle × available design transfer readiness cycles) to the inputs above produces each figure below.
  • At this operating point the engine returns 1,844 units for good design transfer readiness capacity, the number this scenario is built around.
  • At this operating point the engine returns 1,920 units for gross design transfer readiness capacity.
  • At this operating point the engine returns 19.2 units for design transfer readiness downtime loss.
  • At this operating point the engine returns 57.02 units for design transfer readiness yield loss.

How this compares with the baseline

  • Against the tool's baseline example, where expected line uptime during transfer sits at 90% and the headline result is 1,676 units, this scenario comes in 10% above the baseline at 1,844 units.
  • Computes good-unit capacity by taking gross capacity (output per cycle times cycles) and derating it for expected uptime and first-pass yield. 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 design transfer readiness capacity: 1,844 units (headline result)
  • Gross design transfer readiness capacity: 1,920 units
  • Design transfer readiness downtime loss: 19.2 units
  • Design transfer readiness yield loss: 57.02 units

Run it with your numbers

  • Every input above is editable in the live Design Transfer Readiness calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.