NPI, DFM/DFA & Engineering Change worked example

Supplier Launch Readiness at 99% expected supplier line uptime at launch: a worked example

What does the result look like when expected supplier line uptime at launch reaches 99%? The full calculation is worked below with real intermediate numbers. Use it when supplier launch 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

  • Supplier good units produced per launch cycle: 4 units / cycle (unchanged)
  • Launch cycles the supplier can run: 480 cycles (unchanged)
  • Expected supplier line uptime at launch: 99 % (raised for this scenario; the documented default is 90)
  • Expected supplier first-pass yield at launch: 97 % (unchanged)

Working through the calculation

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

How this compares with the baseline

  • Against the tool's baseline example, where expected supplier line uptime at launch sits at 90% and the headline result is 1,676 units, this scenario comes in 10% above the baseline at 1,844 units.
  • A figure at this level is achievable when expected supplier line uptime at launch is genuinely sustained, not just peaked for a shift. It assumes uptime and yield are independent and stable; a supplier whose yield collapses under volume, or whose uptime drops as tooling wears, will deliver less than the model predicts.

Results at a glance

  • Good supplier launch readiness capacity: 1,844 units (headline result)
  • Gross supplier launch readiness capacity: 1,920 units
  • Supplier launch readiness downtime loss: 19.2 units
  • Supplier launch readiness yield loss: 57.02 units

Run it with your numbers

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

Last reviewed 2026-05-12.