Finishing worked example

Rack Density at 65% conveyor uptime: a worked example

Suppose conveyor uptime falls to 65%. This page works the full calculation at that level so you can see exactly which result moves and by how much. Estimate good parts per hour from parts per rack, rack cycles, uptime, and first-pass yield.

The inputs for this scenario

  • Parts hung per rack: 24 parts / cycle (held at the documented default)
  • Rack index cycles per hour: 18 cycles / hr (held at the documented default)
  • Conveyor uptime: 65 % (the input this scenario stresses; the baseline uses 90)
  • First-pass coating yield: 97 % (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Gross capacity = positions/rate × cycles.
  • Good output capacity works out to 272 parts / rack at these inputs, and this is the headline figure for the scenario.
  • Gross capacity works out to 432 parts / rack at these inputs.
  • Uptime loss works out to 151 parts / rack at these inputs.
  • Yield loss works out to 8.42 parts / rack at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where conveyor uptime sits at 90% and the headline result is 377 parts / rack, this scenario comes in 27.78% below the baseline at 272 parts / rack.
  • It computes good parts per rack by taking parts-per-rack times cycles as gross capacity, then de-rating for conveyor uptime and first-pass coating yield. When the numbers land here, the stressed input is the lever to work; the walkthrough above shows exactly how much each output recovers as it climbs back toward the baseline.

Results at a glance

  • Good output capacity: 272 parts / rack (headline result)
  • Gross capacity: 432 parts / rack
  • Uptime loss: 151 parts / rack
  • Yield loss: 8.42 parts / rack

Run it with your numbers

  • To rerun this with your own numbers, open the live Rack Density calculator, set conveyor uptime to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.