Office, School & Institutional Products worked example

SKU Replenishment Quantity at 99% expected line uptime: a worked example

What does the result look like when expected line uptime reaches 99%? The full calculation is worked below with real intermediate numbers. Use it when sku replenishment quantity in office, school and institutional products is being asked to take on more work and you need to know if there is room.

The inputs for this scenario

  • Replenishment output per production cycle: 4 units / cycle (unchanged)
  • Available production cycles in the window: 480 cycles (unchanged)
  • Expected line uptime: 99 % (raised for this scenario; the documented default is 90)
  • Expected first-pass yield: 97 % (unchanged)

Working through the calculation

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

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 10% above the baseline at 1,844 units.
  • A figure at this level is achievable when expected line uptime is genuinely sustained, not just peaked for a shift. It uses single average uptime and yield figures, so it won't capture a line that degrades over a long run or a SKU with bimodal scrap behavior.

Results at a glance

  • Good SKU replenishment quantity capacity: 1,844 units (headline result)
  • Gross SKU replenishment quantity capacity: 1,920 units
  • SKU replenishment quantity downtime loss: 19.2 units
  • SKU replenishment quantity yield loss: 57.02 units

Run it with your numbers

  • Every input above is editable in the live SKU Replenishment Quantity calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.