Transformers, Coils & Magnetics Manufacturing worked example

Capacity Per Shift at 65% winding cell uptime: a worked example

Here is what the math looks like when conditions slip. We hold every other input steady and drop winding cell uptime to 65%, then walk the calculation through step by step. Capacity Per Shift is the number of good transformers, coils, or magnetic assemblies a winding cell can realistically finish in one shift after downtime and scrap are removed.

The inputs for this scenario

  • Coils completed per winding cycle: 4 units / cycle (held at the documented default)
  • Winding cycles available in the shift: 480 cycles (held at the documented default)
  • Winding cell uptime: 65 % (the input this scenario stresses; the baseline uses 90)
  • First-pass coil yield: 97 % (held at the documented default)

Working through the calculation

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

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 27.78% below the baseline at 1,211 units.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to winding cell uptime, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. 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: 1,211 units (headline result)
  • Gross capacity: 1,920 units
  • Uptime loss: 672 units
  • Yield loss: 37.44 units

Run it with your numbers

  • To rerun this with your own numbers, open the live Capacity Per Shift calculator, set winding cell uptime to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.