Sheet Metal Stamping & Press Lines worked example

Downtime Loss at 99% target availability: a worked example

What does the result look like when target availability reaches 99%? The full calculation is worked below with real intermediate numbers. Use it when downtime loss in sheet metal stamping and press lines needs a clean rate and gap-to-target you can put on a tier board.

The inputs for this scenario

  • Press downtime this period: 8 hr-equivalent units (unchanged)
  • Total scheduled press time: 250 hr-equivalent units (unchanged)
  • Target availability: 99 % (raised for this scenario; the documented default is 95)

Working through the calculation

  • Applying the documented formula (Downtime Loss rate = affected amount ÷ total amount) to the inputs above produces each figure below.
  • At this operating point the engine returns 3.2 hr for rate, the number this scenario is built around.
  • At this operating point the engine returns 95.8 points for gap to target.
  • At this operating point the engine returns 8 count for affected count.
  • At this operating point the engine returns 250 count for total count.

How this compares with the baseline

  • Against the tool's baseline example, where target availability sits at 95% and the headline result is 3.2 hr, this scenario lands almost exactly on the baseline at 3.2 hr.
  • A figure at this level is achievable when target availability is genuinely sustained, not just peaked for a shift. It treats all downtime as one bucket; it will not tell you whether losses are dominated by die faults, coil changes, or misfeeds — you still need a Pareto of stop reasons.

Results at a glance

  • Rate: 3.2 hr (headline result)
  • Gap to target: 95.8 points
  • Affected count: 8 count
  • Total count: 250 count

Run it with your numbers

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

Last reviewed 2026-05-12.