Process Manufacturing worked example

Process Capacity at 63% expected line uptime: a worked example

Here is what the math looks like when conditions slip. We hold every other input steady and drop expected line uptime to 63%, then walk the calculation through step by step. Estimate good process capacity from batch size, available cycles, uptime, and yield.

The inputs for this scenario

  • Good output per batch or cycle: 1 batches / cycle (held at the documented default)
  • Available process cycles in the period: 42 cycles (held at the documented default)
  • Expected line uptime: 63 % (the input this scenario stresses; the baseline uses 88)
  • Expected first-pass process yield: 96 % (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Gross process capacity = output per batch or cycle × available cycles.
  • Good output capacity works out to 25.4 batches at these inputs, and this is the headline figure for the scenario.
  • gross process capacity works out to 42 batches at these inputs.
  • capacity lost to downtime works out to 15.54 batches at these inputs.
  • capacity lost to yield works out to 1.06 batches at these inputs.

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 28.41% below the baseline at 25.4 batches.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to expected line uptime, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. 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: 25.4 batches (headline result)
  • gross process capacity: 42 batches
  • capacity lost to downtime: 15.54 batches
  • capacity lost to yield: 1.06 batches

Run it with your numbers

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

Last reviewed 2026-05-12.