Thermal Spray, Hardfacing & Wear Coatings worked example

Spray Time Per Part at 7.2% non-productive time allowance: a worked example

Here is what the math looks like when conditions slip. We hold every other input steady and drop non-productive time allowance to 7.2%, then walk the calculation through step by step. Spray time per part converts a coating workload into a realistic cycle time, so a thermal spray cell knows how long the gun-on and handling time will actually run.

The inputs for this scenario

  • Coating passes or volume to deposit: 120 units (held at the documented default)
  • Deposition (spray) rate: 12 units / hr (held at the documented default)
  • Non-productive time allowance: 7.2 % (the input this scenario stresses; the baseline uses 10)

Working through the calculation

  • The calculation starts from the formula this tool documents: Base spray time per part time = required work รท processing rate.
  • Adjusted run time works out to 10.72 hr at these inputs, and this is the headline figure for the scenario.
  • Base run time works out to 10 hr at these inputs.
  • Allowance applied works out to 7.2 % at these inputs.
  • Process rate works out to 12 pieces / min at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where non-productive time allowance sits at 10% and the headline result is 11 hr, this scenario comes in 2.55% below the baseline at 10.72 hr.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to non-productive time allowance, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. It models spray and handling time only; it does not include grit-blast prep, masking, cooldown between coats, or post-spray grinding, which must be added separately for a full cycle.

Results at a glance

  • Adjusted run time: 10.72 hr (headline result)
  • Base run time: 10 hr
  • Allowance applied: 7.2 %
  • Process rate: 12 pieces / min

Run it with your numbers

  • To rerun this with your own numbers, open the live Spray Time Per Part calculator, set non-productive time allowance to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.