Transformers, Coils & Magnetics Manufacturing worked example

Capacity Per Shift at 99% winding cell uptime: a worked example

What does the result look like when winding cell uptime reaches 99%? The full calculation is worked below with real intermediate numbers. Use it when capacity per shift in transformers, coils and magnetics manufacturing is being asked to take on more work and you need to know if there is room.

The inputs for this scenario

  • Coils completed per winding cycle: 4 units / cycle (unchanged)
  • Winding cycles available in the shift: 480 cycles (unchanged)
  • Winding cell uptime: 99 % (raised for this scenario; the documented default is 90)
  • First-pass coil yield: 97 % (unchanged)

Working through the calculation

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

How this compares with the baseline

  • Against the tool's baseline example, where winding cell uptime sits at 90% and the headline result is 1,676 units, this scenario comes in 10% above the baseline at 1,844 units.
  • A figure at this level is achievable when winding cell uptime is genuinely sustained, not just peaked for a shift. It models a steady-state shift; a big changeover, a wire-reel outage, or a new operator ramping can invalidate the estimate, so revisit it when conditions change.

Results at a glance

  • Good output capacity: 1,844 units (headline result)
  • Gross capacity: 1,920 units
  • Uptime loss: 19.2 units
  • Yield loss: 57.02 units

Run it with your numbers

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

Last reviewed 2026-05-12.