Textiles & Apparel Manufacturing worked example

Bundle Size Capacity at 99% bundling station uptime: a worked example

Push bundling station uptime up to 99% and the picture changes. This example computes every intermediate figure at that operating point. Use it when bundle size capacity in textiles and apparel manufacturing is being asked to take on more work and you need to know if there is room.

The inputs for this scenario

  • Garments bundled per tie-off cycle: 4 units / cycle (unchanged)
  • Bundling cycles available per shift: 480 cycles (unchanged)
  • Bundling station uptime: 99 % (raised for this scenario; the documented default is 90)
  • First-pass bundle accuracy (correct count and mix): 97 % (unchanged)

Working through the calculation

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

How this compares with the baseline

  • Against the tool's baseline example, where bundling station uptime sits at 90% and the headline result is 1,676 units, this scenario comes in 10% above the baseline at 1,844 units.
  • It multiplies bundles per cycle by available cycles for gross capacity, then applies uptime and first-pass accuracy to yield the good bundle count. The value of this scenario is the size of the gap it exposes: that gap, priced out over a year, is the budget you can justify spending to close it.

Results at a glance

  • Good bundle size capacity: 1,844 units (headline result)
  • Gross bundle size capacity: 1,920 units
  • Bundle size capacity downtime loss: 19.2 units
  • Bundle size capacity yield loss: 57.02 units

Run it with your numbers

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

Last reviewed 2026-05-12.