QMS, CAPA & Quality System Management worked example

Control Plan Completeness at 65% expected process uptime under the control plan: a worked example

Suppose expected process uptime under the control plan 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 control plan completeness for qms, capa and quality system management using production-ready inputs so teams can confirm whether capacity can cover demand before committing the schedule.

The inputs for this scenario

  • Characteristics controlled per production cycle: 4 units / cycle (held at the documented default)
  • Production cycles available in the period: 480 cycles (held at the documented default)
  • Expected process uptime under the control plan: 65 % (the input this scenario stresses; the baseline uses 90)
  • Expected first-pass yield under the control plan: 97 % (held at the documented default)

Working through the calculation

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

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 27.78% below the baseline at 1,211 units.
  • It computes good, in-control capacity by discounting gross capacity (output per cycle times cycles) for expected uptime and first-pass yield. 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 control plan completeness capacity: 1,211 units (headline result)
  • Gross control plan completeness capacity: 1,920 units
  • Control plan completeness downtime loss: 672 units
  • Control plan completeness yield loss: 37.44 units

Run it with your numbers

  • To rerun this with your own numbers, open the live Control Plan Completeness calculator, set expected process uptime under the control plan to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.