Thermal Spray, Hardfacing & Wear Coatings worked example

Coating Thickness Buildup at 65% booth productive-time efficiency: a worked example

This worked example runs the coating thickness buildup numbers for a tougher week than the baseline: 65% booth productive-time efficiency instead of the typical 90%. On a busy thermal spray line, knowing how many parts a booth actually clears per hour drives scheduling, capacity planning and delivery promises.

The inputs for this scenario

  • Total coated parts completed: 1,200 units (held at the documented default)
  • Spray booth runtime: 8 hr (held at the documented default)
  • Booth productive-time efficiency: 65 % (the input this scenario stresses; the baseline uses 90)

Working through the calculation

  • The calculation starts from the formula this tool documents: Raw coating thickness buildup = completed output รท runtime.
  • Effective throughput works out to 97.5 units at these inputs, and this is the headline figure for the scenario.
  • Raw throughput works out to 150 units at these inputs.
  • Efficiency works out to 65 % at these inputs.
  • Runtime works out to 8 hr at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where booth productive-time efficiency sits at 90% and the headline result is 135 units, this scenario comes in 27.78% below the baseline at 97.5 units.
  • Use it when planning booth capacity, setting a throughput standard, or quantifying how much idle and changeover time is costing a cell. A result at this level usually justifies acting on the stressed input before touching anything else, because every other figure in the table is downstream of it.

Results at a glance

  • Effective throughput: 97.5 units (headline result)
  • Raw throughput: 150 units
  • Efficiency: 65 %
  • Runtime: 8 hr

Run it with your numbers

  • To rerun this with your own numbers, open the live Coating Thickness Buildup calculator, set booth productive-time efficiency to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.