Textiles & Apparel Manufacturing worked example

Bundle Size Capacity at 65% bundling station uptime: a worked example

Here is what the math looks like when conditions slip. We hold every other input steady and drop bundling station uptime to 65%, then walk the calculation through step by step. Estimate bundle size capacity for textiles and apparel manufacturing using production-ready inputs so teams can confirm whether capacity can cover demand before committing the schedule.

The inputs for this scenario

  • Garments bundled per tie-off cycle: 4 units / cycle (held at the documented default)
  • Bundling cycles available per shift: 480 cycles (held at the documented default)
  • Bundling station uptime: 65 % (the input this scenario stresses; the baseline uses 90)
  • First-pass bundle accuracy (correct count and mix): 97 % (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Gross bundle size capacity = bundle size capacity output per cycle × available bundle size capacity cycles.
  • Good bundle size capacity works out to 1,211 units at these inputs, and this is the headline figure for the scenario.
  • Gross bundle size capacity works out to 1,920 units at these inputs.
  • Bundle size capacity downtime loss works out to 672 units at these inputs.
  • Bundle size capacity yield loss works out to 37.44 units at these inputs.

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 27.78% below the baseline at 1,211 units.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to bundling station uptime, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. It uses static uptime and yield factors, so it won't reflect a mid-shift jam or a batch of miscut panels that suddenly wrecks bundle accuracy.

Results at a glance

  • Good bundle size capacity: 1,211 units (headline result)
  • Gross bundle size capacity: 1,920 units
  • Bundle size capacity downtime loss: 672 units
  • Bundle size capacity yield loss: 37.44 units

Run it with your numbers

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

Last reviewed 2026-05-12.