Wire Harness, Cable & Electromechanical Assembly worked example

Assembly Cell Capacity at 65% expected cell uptime: a worked example

Suppose expected cell uptime falls to 65%. This page works the full calculation at that level so you can see exactly which result moves and by how much. Estimate assembly cell capacity for wire harness, cable and electromechanical assembly using production-ready inputs so teams can confirm whether capacity can cover demand before committing the schedule.

The inputs for this scenario

  • Harnesses built per assembly cycle: 4 units / cycle (held at the documented default)
  • Available assembly cycles per period: 480 cycles (held at the documented default)
  • Expected cell uptime: 65 % (the input this scenario stresses; the baseline uses 90)
  • Expected first-pass yield: 97 % (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Gross assembly cell capacity = assembly cell capacity output per cycle × available assembly cell capacity cycles.
  • Good assembly cell capacity works out to 1,211 units at these inputs, and this is the headline figure for the scenario.
  • Gross assembly cell capacity works out to 1,920 units at these inputs.
  • Assembly cell capacity downtime loss works out to 672 units at these inputs.
  • Assembly cell capacity yield loss works out to 37.44 units at these inputs.

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 27.78% below the baseline at 1,211 units.
  • It computes good (shippable) cell capacity by taking gross output and multiplying by uptime and first-pass yield, and it breaks out the units lost to downtime and to yield separately. When the numbers land here, the stressed input is the lever to work; the walkthrough above shows exactly how much each output recovers as it climbs back toward the baseline.

Results at a glance

  • Good assembly cell capacity: 1,211 units (headline result)
  • Gross assembly cell capacity: 1,920 units
  • Assembly cell capacity downtime loss: 672 units
  • Assembly cell capacity yield loss: 37.44 units

Run it with your numbers

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

Last reviewed 2026-05-12.