PPE & Infection Control Products worked example

Demand Surge Capacity at 65% sustainable uptime under surge running: a worked example in ppe & infection control products

Suppose sustainable uptime under surge running 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 demand surge capacity for ppe and infection control products using production-ready inputs so teams can confirm whether capacity can cover demand before committing the schedule.

The inputs for this scenario

  • Surge output per cycle at max rate: 4 units / cycle (held at the documented default)
  • Surge cycles available (extra shifts/overtime): 480 cycles (held at the documented default)
  • Sustainable uptime under surge running: 65 % (the input this scenario stresses; the baseline uses 90)
  • First-pass yield under surge running: 97 % (held at the documented default)

Working through the calculation

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

How this compares with the baseline

  • Against the tool's baseline example, where sustainable uptime under surge running sits at 90% and the headline result is 1,676 units, this scenario comes in 27.78% below the baseline at 1,211 units.
  • It computes good sellable capacity under surge conditions by discounting the extra gross capacity for the lower uptime and yield that hard running produces. 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 demand surge capacity: 1,211 units (headline result)
  • Gross demand surge capacity: 1,920 units
  • Demand surge capacity downtime loss: 672 units
  • Demand surge capacity yield loss: 37.44 units

Run it with your numbers

  • To rerun this with your own numbers, open the live Demand Surge Capacity calculator, set sustainable uptime under surge running to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.