QMS, CAPA & Quality System Management worked example

Control Plan Completeness at 99% expected process uptime under the control plan: a worked example

This scenario runs the control plan completeness calculation on the strong side: 99% expected process uptime under the control plan, with every other input held at its documented default. Use it when control plan completeness in qms, capa and quality system management is being asked to take on more work and you need to know if there is room.

The inputs for this scenario

  • Characteristics controlled per production cycle: 4 units / cycle (unchanged)
  • Production cycles available in the period: 480 cycles (unchanged)
  • Expected process uptime under the control plan: 99 % (raised for this scenario; the documented default is 90)
  • Expected first-pass yield under the control plan: 97 % (unchanged)

Working through the calculation

  • Applying the documented formula (Gross control plan completeness capacity = control plan completeness output per cycle × available control plan completeness cycles) to the inputs above produces each figure below.
  • At this operating point the engine returns 1,844 units for good control plan completeness capacity, the number this scenario is built around.
  • At this operating point the engine returns 1,920 units for gross control plan completeness capacity.
  • At this operating point the engine returns 19.2 units for control plan completeness downtime loss.
  • At this operating point the engine returns 57.02 units for control plan completeness yield loss.

How this compares with the baseline

  • Against the tool's baseline example, where expected process uptime under the control plan sits at 90% and the headline result is 1,676 units, this scenario comes in 10% above the baseline at 1,844 units.
  • Use it when validating a control plan against production demand or estimating conforming output for a run. Treat this as a target state: the delta against the baseline quantifies what the improvement is worth before you commit to chasing it.

Results at a glance

  • Good control plan completeness capacity: 1,844 units (headline result)
  • Gross control plan completeness capacity: 1,920 units
  • Control plan completeness downtime loss: 19.2 units
  • Control plan completeness yield loss: 57.02 units

Run it with your numbers

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

Last reviewed 2026-05-12.