Safety & Workforce worked example

Headcount Capacity at 99% line uptime: a worked example

This scenario runs the headcount capacity calculation on the strong side: 99% line uptime, with every other input held at its documented default. Use it when headcount capacity in safety and workforce is being asked to take on more work and you need to know if there is room.

The inputs for this scenario

  • Good output per staffed cycle: 120 units / cycle (unchanged)
  • Available production cycles: 40 cycles (unchanged)
  • Line uptime: 99 % (raised for this scenario; the documented default is 90)
  • First-pass yield: 97 % (unchanged)

Working through the calculation

  • Applying the documented formula (Good capacity = cycle capacity × available cycles × uptime × yield) to the inputs above produces each figure below.
  • At this operating point the engine returns 4,609 hr for good headcount capacity, the number this scenario is built around.
  • At this operating point the engine returns 4,800 hr for gross headcount capacity.
  • At this operating point the engine returns 48 hr for headcount capacity downtime loss.
  • At this operating point the engine returns 143 hr for headcount capacity yield loss.

How this compares with the baseline

  • Against the tool's baseline example, where line uptime sits at 90% and the headline result is 4,190 hr, this scenario comes in 10% above the baseline at 4,609 hr.
  • Use it when committing capacity to a customer, comparing crewing scenarios, or quantifying what a reliability or quality improvement is worth in output. 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 headcount capacity: 4,609 hr (headline result)
  • Gross headcount capacity: 4,800 hr
  • Headcount capacity downtime loss: 48 hr
  • Headcount capacity yield loss: 143 hr

Run it with your numbers

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

Last reviewed 2026-05-12.