Outdoor Power Equipment worked example

Capacity Gap at 99% build line uptime: a worked example in outdoor power equipment

This scenario runs the capacity gap calculation on the strong side: 99% build line uptime, with every other input held at its documented default. a production planner needs realistic good output per shift to compare against demand and spot a capacity gap

The inputs for this scenario

  • Units built per cycle: 4 units / cycle (unchanged)
  • Available build cycles: 480 cycles (unchanged)
  • Build line uptime: 99 % (raised for this scenario; the documented default is 90)
  • Assembly first-pass yield: 97 % (unchanged)

Working through the calculation

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

How this compares with the baseline

  • Against the tool's baseline example, where build 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.
  • Use it when sizing a shift's committed output, validating a takt plan against firm dealer orders, or deciding whether overtime or a yield project closes a shortfall. Treat this as a target state: the delta against the baseline quantifies what the improvement is worth before you commit to chasing it.

Results at a glance

  • Good build capacity per shift: 1,844 units (headline result)
  • Gross build capacity: 1,920 units
  • Build line downtime loss: 19.2 units
  • Assembly yield loss: 57.02 units

Run it with your numbers

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

Last reviewed 2026-05-12.