Outdoor Power Equipment worked example

Capacity Gap at 65% build line uptime: a worked example in outdoor power equipment

Here is what the math looks like when conditions slip. We hold every other input steady and drop build line uptime to 65%, then walk the calculation through step by step. Estimate good buildable units per shift from cycle output, available cycles, line uptime, and first-pass yield to test capacity against demand.

The inputs for this scenario

  • Units built per cycle: 4 units / cycle (held at the documented default)
  • Available build cycles: 480 cycles (held at the documented default)
  • Build line uptime: 65 % (the input this scenario stresses; the baseline uses 90)
  • Assembly first-pass yield: 97 % (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Gross build capacity = units built per cycle × available build cycles.
  • Good build capacity per shift works out to 1,211 units at these inputs, and this is the headline figure for the scenario.
  • Gross build capacity works out to 1,920 units at these inputs.
  • Build line downtime loss works out to 672 units at these inputs.
  • Assembly yield loss works out to 37.44 units at these inputs.

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 27.78% below the baseline at 1,211 units.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to build line uptime, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. It assumes uptime and first-pass yield are independent multipliers and stable across the run; a line with batch-correlated defects or a single chronic bottleneck station can deviate from this simple product.

Results at a glance

  • Good build capacity per shift: 1,211 units (headline result)
  • Gross build capacity: 1,920 units
  • Build line downtime loss: 672 units
  • Assembly yield loss: 37.44 units

Run it with your numbers

  • To rerun this with your own numbers, open the live Capacity Gap calculator, set build line uptime to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.