Wire Drawing & Rod Processing worked example
Wire Spool Capacity at 99% winder uptime: a worked example
What does the result look like when winder uptime reaches 99%? The full calculation is worked below with real intermediate numbers. Use it when wire spool capacity in wire drawing and rod processing is being asked to take on more work and you need to know if there is room.
The inputs for this scenario
- Wire spooled per winding cycle: 4 units / cycle (unchanged)
- Winding cycles available per shift: 480 cycles (unchanged)
- Winder uptime: 99 % (raised for this scenario; the documented default is 90)
- First-pass spool yield: 97 % (unchanged)
Working through the calculation
- Applying the documented formula (Gross wire spool capacity 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.
- A figure at this level is achievable when winder uptime is genuinely sustained, not just peaked for a shift. It assumes uptime and yield are independent, steady-state percentages; a die that degrades mid-run or a single long web break will make actual output diverge from this estimate.
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 Wire Spool Capacity calculator, which recalculates instantly and can be shared with the inputs intact.
Last reviewed 2026-05-12.