Wire Harness, Cable & Electromechanical Assembly worked example

Cable Bend Radius Check at 65% inspection station uptime: a worked example

Here is what the math looks like when conditions slip. We hold every other input steady and drop inspection station uptime to 65%, then walk the calculation through step by step. Estimate cable bend radius check 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

  • Cables checked per inspection cycle: 4 units / cycle (held at the documented default)
  • Available inspection cycles in the window: 480 cycles (held at the documented default)
  • Inspection station uptime: 65 % (the input this scenario stresses; the baseline uses 90)
  • First-pass bend-radius pass rate: 97 % (held at the documented default)

Working through the calculation

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

How this compares with the baseline

  • Against the tool's baseline example, where inspection station 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.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to inspection station uptime, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. It assumes pass rate is steady; if an upstream routing fixture drifts, first-pass pass rate falls in bursts and this average understates the worst-window loss.

Results at a glance

  • Good cable bend radius check capacity: 1,211 units (headline result)
  • Gross cable bend radius check capacity: 1,920 units
  • Cable bend radius check downtime loss: 672 units
  • Cable bend radius check yield loss: 37.44 units

Run it with your numbers

  • To rerun this with your own numbers, open the live Cable Bend Radius Check calculator, set inspection station uptime to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.