Finishing worked example

Rack Loading Capacity at 65% line availability: a worked example

Here is what the math looks like when conditions slip. We hold every other input steady and drop line availability to 65%, then walk the calculation through step by step. Estimate rack loading capacity from rack positions, cycles, uptime, and first-pass yield.

The inputs for this scenario

  • Loadable rack positions: 24 parts / cycle (held at the documented default)
  • Rack index cycles per hour: 18 cycles / hr (held at the documented default)
  • Line availability: 65 % (the input this scenario stresses; the baseline uses 90)
  • First-pass finish 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 at these inputs, and this is the headline figure for the scenario.
  • Gross capacity works out to 432 parts at these inputs.
  • Uptime loss works out to 151 parts at these inputs.
  • Yield loss works out to 8.42 parts at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where line availability sits at 90% and the headline result is 377 parts, this scenario comes in 27.78% below the baseline at 272 parts.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to line availability, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. It assumes positions are always fully loaded and that availability and yield hold steady; a changing product mix, color-change frequency, or rack-fill shortfalls will move the true number.

Results at a glance

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

Run it with your numbers

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

Last reviewed 2026-05-12.