Outdoor Power Equipment worked example

Assembly Line Throughput at 66% assembly line uptime: a worked example

This worked example runs the assembly line throughput numbers for a tougher week than the baseline: 66% assembly line uptime instead of the typical 91%. Estimate good units off the assembly line per shift from units per cycle, available cycles, line uptime, and first-pass yield.

The inputs for this scenario

  • Units off line per cycle: 5 units / cycle (held at the documented default)
  • Available assembly cycles: 450 cycles (held at the documented default)
  • Assembly line uptime: 66 % (the input this scenario stresses; the baseline uses 91)
  • End-of-line first-pass yield: 96 % (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Gross assembly throughput = units off line per cycle × available assembly cycles.
  • Good units off line per shift works out to 1,426 units at these inputs, and this is the headline figure for the scenario.
  • Gross assembly throughput works out to 2,250 units at these inputs.
  • Assembly downtime loss works out to 765 units at these inputs.
  • End-of-line yield loss works out to 59.4 units at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where assembly line uptime sits at 91% and the headline result is 1,966 units, this scenario comes in 27.47% below the baseline at 1,426 units.
  • Use it when committing to a daily build plan, evaluating an OEE improvement, or checking whether the line can meet a customer order on time. 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 units off line per shift: 1,426 units (headline result)
  • Gross assembly throughput: 2,250 units
  • Assembly downtime loss: 765 units
  • End-of-line yield loss: 59.4 units

Run it with your numbers

  • To rerun this with your own numbers, open the live Assembly Line Throughput calculator, set assembly line uptime to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.