Conveyors calculator

Reject Station Capacity Calculator

Use this calculator when rejected product must be inspected, diverted, scanned, or manually handled without backing up the main line. It checks whether the reject station has enough capacity for expected defect flow.

What this calculator does

  • Estimate how many rejected parts a reject, inspection, or diversion station can process per hour.
  • a quality or automation engineer needs to confirm that a reject station will not become a bottleneck
  • The result estimates how many rejected parts per hour the reject station can handle correctly.

Formula used

  • Gross reject station capacity = positions × cycles per position-hour
  • Good reject disposition capacity = gross capacity × uptime × disposition rate

Inputs explained

  • Active reject handling positions: Count reject lanes, inspection benches, robots, or operators assigned to rejects.
  • Reject cycles per position-hour: Use the rate one position can inspect, divert, or disposition rejected parts.
  • Reject station uptime: Reduce for full bins, printer faults, scanner faults, or operator waits.
  • Successful reject disposition rate: Use the percentage correctly sorted, labeled, reworked, or scrapped.

How to use the result

  • Use it before adding inspection labor, reject conveyors, bins, barcode stations, or rework routing.
  • It does not predict reject arrival bursts; accumulation may still be needed upstream of the station.

Common questions

  • What is Reject Station Capacity for? Estimate how many rejected parts a reject, inspection, or diversion station can process per hour.
  • What information do I need before using it? You need reject handling positions, cycles per position-hour, uptime, and successful disposition rate.
  • When is the result only an estimate? The result is approximate when reject mix, inspection time, or disposition path varies by defect type.
  • How can I use the result on the line? Use capacity to decide whether the reject station can keep up with expected scrap or needs more lanes, labor, or automation.

Last reviewed 2026-05-12.