Printing, Labels & Industrial Converting worked example

Print Inspection Sample Size at 65% inspection station uptime: a worked example

Here is what the math looks like when conditions slip. We hold every other input steady and drop inspection station uptime to 65%, then walk the calculation through step by step. Estimate print inspection sample size for printing, labels and industrial converting using production-ready inputs so teams can confirm whether capacity can cover demand before committing the schedule.

The inputs for this scenario

  • Labels inspected per cycle: 4 units / cycle (held at the documented default)
  • Inspection cycles available: 480 cycles (held at the documented default)
  • Inspection station uptime: 65 % (the input this scenario stresses; the baseline uses 90)
  • First-pass inspection yield: 97 % (held at the documented default)

Working through the calculation

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

How this compares with the baseline

  • Against the tool's baseline example, where inspection station 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 inspection station uptime, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. It assumes uptime and first-pass yield are stable averages; a mid-shift jam or a defect cluster that spikes rejects will drop actual good capacity below the modeled figure.

Results at a glance

  • Good print inspection sample size capacity: 1,211 units (headline result)
  • Gross print inspection sample size capacity: 1,920 units
  • Print inspection sample size downtime loss: 672 units
  • Print inspection sample size yield loss: 37.44 units

Run it with your numbers

  • To rerun this with your own numbers, open the live Print Inspection Sample Size calculator, set inspection station uptime to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.