Transformers, Coils & Magnetics Manufacturing worked example

Turns Count at 65% winder uptime: a worked example

Here is what the math looks like when conditions slip. We hold every other input steady and drop winder uptime to 65%, then walk the calculation through step by step. Turns Count capacity tells a magnetics shop how many good wound coils a winder can actually deliver in a shift once uptime and first-pass yield are stripped out of the theoretical number.

The inputs for this scenario

  • Coils wound per machine cycle: 4 units / cycle (held at the documented default)
  • Available winding cycles per shift: 480 cycles (held at the documented default)
  • Winder uptime: 65 % (the input this scenario stresses; the baseline uses 90)
  • First-pass winding yield: 97 % (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Gross turns count 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 winder 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 winder uptime, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. It assumes uptime and yield are steady across the shift; a single bad wire spool or a mid-shift tooling change can move both far below the averages you entered.

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 Turns Count calculator, set winder uptime to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.