Rail, Transit & Rolling Stock Manufacturing worked example

Door System Test Capacity at 99% test rig uptime: a worked example

Push test rig uptime up to 99% and the picture changes. This example computes every intermediate figure at that operating point. Use it when door system test capacity in rail, transit and rolling stock manufacturing is being asked to take on more work and you need to know if there is room.

The inputs for this scenario

  • Doors validated per test cell cycle: 4 units / cycle (unchanged)
  • Scheduled test cell cycles available: 480 cycles (unchanged)
  • Test rig uptime (no faults or waiting): 99 % (raised for this scenario; the documented default is 90)
  • First-pass yield on door endurance/leak test: 97 % (unchanged)

Working through the calculation

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

How this compares with the baseline

  • Against the tool's baseline example, where test rig uptime sits at 90% and the headline result is 1,676 units, this scenario comes in 10% above the baseline at 1,844 units.
  • It computes good (validated) door system test capacity by derating gross rig throughput for expected uptime and first-pass yield. The value of this scenario is the size of the gap it exposes: that gap, priced out over a year, is the budget you can justify spending to close it.

Results at a glance

  • Good door system test capacity: 1,844 units (headline result)
  • Gross door system test capacity: 1,920 units
  • Door system test capacity downtime loss: 19.2 units
  • Door system test capacity yield loss: 57.02 units

Run it with your numbers

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

Last reviewed 2026-05-12.