Single-Use Bioprocess Assemblies worked example

Capacity Gap at 99% assembly line uptime: a worked example in single-use bioprocess assemblies

What does the result look like when assembly line uptime reaches 99%? The full calculation is worked below with real intermediate numbers. Use it when capacity gap in single-use bioprocess assemblies is being asked to take on more work and you need to know if there is room.

The inputs for this scenario

  • Assemblies produced per weld/build cycle: 4 units / cycle (unchanged)
  • Available build cycles in horizon: 480 cycles (unchanged)
  • Assembly line uptime: 99 % (raised for this scenario; the documented default is 90)
  • First-pass integrity yield: 97 % (unchanged)

Working through the calculation

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

How this compares with the baseline

  • Against the tool's baseline example, where assembly line uptime sits at 90% and the headline result is 1,676 units, this scenario comes in 10% above the baseline at 1,844 units.
  • A figure at this level is achievable when assembly line uptime is genuinely sustained, not just peaked for a shift. It assumes uptime and first-pass yield are independent and steady; correlated failures (a bad tubing lot driving both scrap and rework downtime) will make real good capacity lower than the model shows.

Results at a glance

  • Good capacity gap capacity: 1,844 units (headline result)
  • Gross capacity gap capacity: 1,920 units
  • Capacity gap downtime loss: 19.2 units
  • Capacity gap yield loss: 57.02 units

Run it with your numbers

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

Last reviewed 2026-05-12.