Textiles & Apparel Manufacturing calculator
Garment Packout Capacity Calculator
Garment packout capacity is the number of saleable, correctly finished garments a pack-out line can complete in a shift after uptime and quality losses. Packout supervisors and distribution planners use it to promise realistic ship quantities instead of theoretical line speeds. It separates gross capacity from the good units that actually pass inspection and leave the dock. Knowing the split between downtime loss and yield loss tells you exactly where to attack.
What this calculator does
- Estimate garment packout capacity for textiles and apparel manufacturing using production-ready inputs so teams can confirm whether capacity can cover demand before committing the schedule.
- Use it when garment packout capacity in textiles and apparel manufacturing is being asked to take on more work and you need to know if there is room.
- It multiplies output per cycle by available cycles for gross capacity, then discounts by uptime and first-pass yield to give good, shippable units.
Formula used
- Gross garment packout capacity = garment packout capacity output per cycle × available garment packout capacity cycles
- Good garment packout capacity = gross capacity × expected garment packout capacity uptime × expected garment packout capacity first-pass yield
Inputs explained
- Garments packed per packout cycle:
- Available packout cycles in the shift:
- Expected packout line uptime:
- Expected packout first-pass yield:
How to use the result
- Use it when committing shift ship quantities or diagnosing whether a shortfall came from downtime or defects.
- It assumes uptime and yield are independent flat rates; a stoppage that also causes a defect cluster is not modeled separately.
Common questions
- How do you calculate garment packout capacity? Multiply units per cycle by cycles for gross, then multiply by uptime and yield. Here 4 x 480 = 1,920 gross, x 90% x 97% = 1,676 good units.
- What is the difference between gross and good packout capacity? Gross is the theoretical 1,920 units if nothing stopped or failed. Good is the 1,676 units that survive 90% uptime and 97% first-pass yield and can actually ship.
- What is a good packout first-pass yield? For finished garment packout, 97-99% is strong because most defects should be caught upstream. The default 97% already costs about 52 units per shift here.
- How much capacity does downtime cost? In this example 10% downtime removes 192 units from the 1,920 gross before yield is even applied, making it the larger loss lever at these settings.
- Uptime vs yield: which should I fix first? Compare the two loss figures. Here downtime loss is 192 units versus 52 units of yield loss, so recovering uptime returns more shippable garments per point of improvement.
Last reviewed 2026-05-12.