Safety & Workforce worked example

Headcount Capacity at 65% line uptime: a worked example

This worked example runs the headcount capacity numbers for a tougher week than the baseline: 65% line uptime instead of the typical 90%. Estimate good labor capacity from crew size, available shifts, uptime, and yield.

The inputs for this scenario

  • Good output per staffed cycle: 120 units / cycle (held at the documented default)
  • Available production cycles: 40 cycles (held at the documented default)
  • Line uptime: 65 % (the input this scenario stresses; the baseline uses 90)
  • First-pass yield: 97 % (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Good capacity = cycle capacity × available cycles × uptime × yield.
  • Good headcount capacity works out to 3,026 hr at these inputs, and this is the headline figure for the scenario.
  • Gross headcount capacity works out to 4,800 hr at these inputs.
  • Headcount capacity downtime loss works out to 1,680 hr at these inputs.
  • Headcount capacity yield loss works out to 93.6 hr at these inputs.

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 27.78% below the baseline at 3,026 hr.
  • Use it when committing capacity to a customer, comparing crewing scenarios, or quantifying what a reliability or quality improvement is worth in output. 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 headcount capacity: 3,026 hr (headline result)
  • Gross headcount capacity: 4,800 hr
  • Headcount capacity downtime loss: 1,680 hr
  • Headcount capacity yield loss: 93.6 hr

Run it with your numbers

  • To rerun this with your own numbers, open the live Headcount Capacity calculator, set line uptime to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.