NPI, DFM/DFA & Engineering Change worked example

Manufacturing Readiness Level at 99% expected process uptime at this mrl: a worked example

Push expected process uptime at this mrl up to 99% and the picture changes. This example computes every intermediate figure at that operating point. Use it when manufacturing readiness level 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

  • Production output per readiness cycle: 4 units / cycle (unchanged)
  • Available MRL assessment cycles: 480 cycles (unchanged)
  • Expected process uptime at this MRL: 99 % (raised for this scenario; the documented default is 90)
  • Expected first-pass yield at this MRL: 97 % (unchanged)

Working through the calculation

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

How this compares with the baseline

  • Against the tool's baseline example, where expected process uptime at this mrl 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 derating gross capacity (output per cycle times cycles) for the uptime and first-pass yield expected at the current MRL. 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 manufacturing readiness level capacity: 1,844 units (headline result)
  • Gross manufacturing readiness level capacity: 1,920 units
  • Manufacturing readiness level downtime loss: 19.2 units
  • Manufacturing readiness level yield loss: 57.02 units

Run it with your numbers

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

Last reviewed 2026-05-12.