Rail, Transit & Rolling Stock Manufacturing worked example

Bogie Assembly Throughput at 65% expected bogie line uptime: a worked example

This worked example runs the bogie assembly throughput numbers for a tougher week than the baseline: 65% expected bogie line uptime instead of the typical 90%. Estimate bogie assembly throughput for rail, transit and rolling stock manufacturing using production-ready inputs so teams can confirm whether capacity can cover demand before committing the schedule.

The inputs for this scenario

  • Bogies completed per assembly cycle: 4 units / cycle (held at the documented default)
  • Available assembly cycles in the period: 480 cycles (held at the documented default)
  • Expected bogie line uptime: 65 % (the input this scenario stresses; the baseline uses 90)
  • Expected first-pass yield: 97 % (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Gross bogie assembly throughput capacity = bogie assembly throughput output per cycle × available bogie assembly throughput cycles.
  • Good bogie assembly throughput capacity works out to 1,211 units at these inputs, and this is the headline figure for the scenario.
  • Gross bogie assembly throughput capacity works out to 1,920 units at these inputs.
  • Bogie assembly throughput downtime loss works out to 672 units at these inputs.
  • Bogie assembly throughput 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 bogie line 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.
  • Use it when sizing a bogie line, matching bogie supply to carbody demand, or quantifying the throughput cost of downtime and defects. A result at this level usually justifies acting on the stressed input before touching anything else, because every other figure in the table is downstream of it.

Results at a glance

  • Good bogie assembly throughput capacity: 1,211 units (headline result)
  • Gross bogie assembly throughput capacity: 1,920 units
  • Bogie assembly throughput downtime loss: 672 units
  • Bogie assembly throughput yield loss: 37.44 units

Run it with your numbers

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

Last reviewed 2026-05-12.