Welding & Fabrication worked example

Fabrication Batch Capacity at 63% weld cell uptime: a worked example

Here is what the math looks like when conditions slip. We hold every other input steady and drop weld cell uptime to 63%, then walk the calculation through step by step. Estimate good weldments per shift from parts per cycle, cycles per shift, weld cell uptime, and first-pass yield.

The inputs for this scenario

  • Parts per weld cycle: 2 parts / cycle (held at the documented default)
  • Available cycles per shift: 75 cycles (held at the documented default)
  • Weld cell uptime: 63 % (the input this scenario stresses; the baseline uses 88)
  • First-pass yield: 96 % (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Gross weld cell capacity = parts per weld cycle × available cycles per shift.
  • Good output capacity works out to 90.72 parts / shift at these inputs, and this is the headline figure for the scenario.
  • Gross capacity works out to 150 parts / shift at these inputs.
  • Uptime loss works out to 55.5 parts / shift at these inputs.
  • Yield loss works out to 3.78 parts / shift at these inputs.

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 28.41% below the baseline at 90.72 parts / shift.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to weld cell uptime, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. 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: 90.72 parts / shift (headline result)
  • Gross capacity: 150 parts / shift
  • Uptime loss: 55.5 parts / shift
  • Yield loss: 3.78 parts / shift

Run it with your numbers

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

Last reviewed 2026-05-12.