| Quantity | Cycle time (min) | Lines | Utilization | Efficiency | Shift hours | Breaks | Setup | Shifts/day | Daily throughput |
|---|---|---|---|---|---|---|---|---|---|
| 1200 units | 4.5 | 2 | 85% | 95% | 8 | 45 min | 20 min | 1 | ~ 178.6 units/day |
| 350 m³ | 6 | 1 | 80% | 100% | 10 | 60 min | 30 min | 2 | ~ 240.0 m³/day |
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Gross rate per line:
GrossRate = 60 / CycleTime -
Net rate per line:
NetRateLine = GrossRate × Utilization × Efficiency -
Total net rate:
TotalNetRate = NetRateLine × ParallelLines -
Effective hours per shift:
EffHours = (ShiftHours×60 − Breaks − Setup) / 60 -
Daily throughput:
Daily = TotalNetRate × EffHours × ShiftsPerDay -
Duration (optional):
Days = Quantity / Daily
- Select an output unit that matches your measurement method.
- Enter cycle time per unit for one crew or production line.
- Add the number of parallel lines running at the same time.
- Set utilization to reflect downtime and small interruptions.
- Set efficiency to match real performance versus baseline.
- Enter shift length, then subtract planned breaks and setup.
- Choose shifts per day to convert shift output to daily output.
- Optionally enter total quantity to estimate completion duration.
Throughput planning for construction operations
Throughput is the achievable output of a crew or process per hour, shift, or day. Early estimates convert scope into workable production targets, helping you balance labor, equipment, access, and material delivery. By using cycle time and realistic loss factors, planners replace optimistic “best case” rates with defendable numbers that can be tracked in the field. It also supports scenario testing for overtime, additional crews, and downtime allowances, so the schedule can be communicated clearly to stakeholders. before procurement and mobilization.
Cycle time and parallel workstreams
Cycle time is the average minutes to complete one repeatable unit on a single line, such as one rebar cage, one precast panel, or one truck load-out. If multiple crews can work independently, model them as parallel lines. This separates decisions: you can shorten cycle time with better methods, or increase lines when space, supervision, and logistics allow.
Utilization and efficiency as controllable factors
Utilization represents the fraction of available time that stays productive after minor stoppages, coordination waits, and small breakdowns. Efficiency adjusts speed while working, reflecting skill level, congestion, weather, or complexity. Keeping them distinct improves troubleshooting: raise utilization by removing bottlenecks, and raise efficiency through training, prefabrication, and clearer work packaging.
Shift structure and nonproductive allowances
A scheduled shift includes nonproductive allowances. Subtract planned breaks, safety briefings, startup checks, and changeovers from shift hours to get effective hours. For multi-shift operations, increase shifts per day instead of inflating utilization. This keeps the estimate aligned with real staffing patterns and highlights when support systems—lighting, maintenance, supervision, and quality coverage—must scale.
Example data and how to use the output
Example data: Quantity 1200 units, cycle time 4.5 minutes, two lines, utilization 85%, efficiency 95%, 8-hour shift, 45 minutes breaks, and 20 minutes setup. The calculator yields about 178.6 units per day and roughly 6.7 working days. Use the output to plan inspection windows, deliveries, handoffs, and contingency buffers, then update inputs with actual counts for ongoing forecasts.