Process Manufacturing worked example

Process Capacity at 99% expected line uptime: a worked example

What does the result look like when expected line uptime reaches 99%? The full calculation is worked below with real intermediate numbers. checking batch, tank, reactor, or packaging capacity for a planning period

The inputs for this scenario

  • Good output per batch or cycle: 1 batches / cycle (unchanged)
  • Available process cycles in the period: 42 cycles (unchanged)
  • Expected line uptime: 99 % (raised for this scenario; the documented default is 88)
  • Expected first-pass process yield: 96 % (unchanged)

Working through the calculation

  • Applying the documented formula (Gross process capacity = output per batch or cycle × available cycles) to the inputs above produces each figure below.
  • At this operating point the engine returns 39.92 batches for good output capacity, the number this scenario is built around.
  • At this operating point the engine returns 42 batches for gross process capacity.
  • At this operating point the engine returns 0.42 batches for capacity lost to downtime.
  • At this operating point the engine returns 1.66 batches for capacity lost to yield.

How this compares with the baseline

  • Against the tool's baseline example, where expected line uptime sits at 88% and the headline result is 35.48 batches, this scenario comes in 12.5% above the baseline at 39.92 batches.
  • A figure at this level is achievable when expected line uptime is genuinely sustained, not just peaked for a shift. Uptime and yield are treated as steady averages; a line with high variability or long changeovers between products may need a more granular OEE model.

Results at a glance

  • Good output capacity: 39.92 batches (headline result)
  • gross process capacity: 42 batches
  • capacity lost to downtime: 0.42 batches
  • capacity lost to yield: 1.66 batches

Run it with your numbers

  • Every input above is editable in the live Process Capacity calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.