Wire Harness, Cable & Electromechanical Assembly worked example

Assembly Cell Capacity at 99% expected cell uptime: a worked example

What does the result look like when expected cell uptime reaches 99%? The full calculation is worked below with real intermediate numbers. Use it when assembly cell capacity in wire harness, cable and electromechanical assembly is being asked to take on more work and you need to know if there is room.

The inputs for this scenario

  • Harnesses built per assembly cycle: 4 units / cycle (unchanged)
  • Available assembly cycles per period: 480 cycles (unchanged)
  • Expected cell uptime: 99 % (raised for this scenario; the documented default is 90)
  • Expected first-pass yield: 97 % (unchanged)

Working through the calculation

  • Applying the documented formula (Gross assembly cell capacity = assembly cell capacity output per cycle × available assembly cell capacity cycles) to the inputs above produces each figure below.
  • At this operating point the engine returns 1,844 units for good assembly cell capacity, the number this scenario is built around.
  • At this operating point the engine returns 1,920 units for gross assembly cell capacity.
  • At this operating point the engine returns 19.2 units for assembly cell capacity downtime loss.
  • At this operating point the engine returns 57.02 units for assembly cell capacity yield loss.

How this compares with the baseline

  • Against the tool's baseline example, where expected cell 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 expected cell uptime is genuinely sustained, not just peaked for a shift. It uses expected uptime and yield as flat averages, so a cell with bursty downtime or a yield problem concentrated in one part number can behave differently than the single-number estimate suggests.

Results at a glance

  • Good assembly cell capacity: 1,844 units (headline result)
  • Gross assembly cell capacity: 1,920 units
  • Assembly cell capacity downtime loss: 19.2 units
  • Assembly cell capacity yield loss: 57.02 units

Run it with your numbers

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

Last reviewed 2026-05-12.