Welding & Fabrication worked example

Fabrication Batch Capacity at 99% weld cell uptime: a worked example

What does the result look like when weld cell uptime reaches 99%? The full calculation is worked below with real intermediate numbers. Use it to set a realistic per-shift output for a weld cell before taking on more work, so capacity claims account for downtime and rework.

The inputs for this scenario

  • Parts per weld cycle: 2 parts / cycle (unchanged)
  • Available cycles per shift: 75 cycles (unchanged)
  • Weld cell uptime: 99 % (raised for this scenario; the documented default is 88)
  • First-pass yield: 96 % (unchanged)

Working through the calculation

  • Applying the documented formula (Gross weld cell capacity = parts per weld cycle × available cycles per shift) to the inputs above produces each figure below.
  • At this operating point the engine returns 143 parts / shift for good output capacity, the number this scenario is built around.
  • At this operating point the engine returns 150 parts / shift for gross capacity.
  • At this operating point the engine returns 1.5 parts / shift for uptime loss.
  • At this operating point the engine returns 5.94 parts / shift for yield loss.

How this compares with the baseline

  • Against the tool's baseline example, where weld cell uptime sits at 88% and the headline result is 127 parts / shift, this scenario comes in 12.5% above the baseline at 143 parts / shift.
  • A figure at this level is achievable when weld cell uptime is genuinely sustained, not just peaked for a shift. It treats uptime and yield as independent flat percentages; in practice a poorly running cell often drives both down together, and the calculator won't capture that correlated failure mode.

Results at a glance

  • Good output capacity: 143 parts / shift (headline result)
  • Gross capacity: 150 parts / shift
  • Uptime loss: 1.5 parts / shift
  • Yield loss: 5.94 parts / shift

Run it with your numbers

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

Last reviewed 2026-05-12.