Transformers, Coils & Magnetics Manufacturing worked example

Turns Count at 99% winder uptime: a worked example

Push winder uptime up to 99% and the picture changes. This example computes every intermediate figure at that operating point. Use it when turns count 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 wound per machine cycle: 4 units / cycle (unchanged)
  • Available winding cycles per shift: 480 cycles (unchanged)
  • Winder uptime: 99 % (raised for this scenario; the documented default is 90)
  • First-pass winding yield: 97 % (unchanged)

Working through the calculation

  • Applying the documented formula (Gross turns count 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 winder uptime sits at 90% and the headline result is 1,676 units, this scenario comes in 10% above the baseline at 1,844 units.
  • It computes the good (sellable) coil output of a winding line by multiplying units per cycle and available cycles, then derating for uptime and first-pass yield. The value of this scenario is the size of the gap it exposes: that gap, priced out over a year, is the budget you can justify spending to close it.

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 Turns Count calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.