Track output rates, batch effects, uptime, and line capacity. Compare scenarios with practical engineering assumptions. Improve planning accuracy using throughput estimates for every shift.
Gross available seconds = hours per shift × 3600 × shifts per day.
Total downtime seconds = (planned downtime + unplanned downtime + setup time × batch count) × 60.
Net runtime seconds = gross available seconds − total downtime seconds.
Ideal cycles = net runtime seconds ÷ cycle time seconds.
Adjusted cycles = ideal cycles × performance factor.
Gross output = adjusted cycles × units per cycle × parallel lines.
Good output = gross output × (1 − scrap rate).
Throughput per hour = good output ÷ scheduled operating hours.
Period output = daily good output × days in period.
Composite efficiency = availability × performance × quality.
Enter the average units produced in one cycle and the cycle duration in seconds. Add the number of parallel lines when more than one machine or lane runs together.
Fill in shift hours, number of shifts, downtime minutes, setup minutes, and batch count. These fields help the estimator separate scheduled time from actual runtime.
Set the scrap rate to remove rejected output and enter the performance factor to reflect actual operating speed versus theoretical speed.
Click the calculate button. The result section appears above the form and summarizes daily throughput, hourly rate, utilization, adjusted cycles, and period output.
Use the CSV option for spreadsheets and the PDF option for printable reports. Review the example table below if you need a sample input set.
| Units/Cycle | Cycle Time | Lines | Shift Hours | Shifts | Downtime | Scrap | Performance | Estimated Good Output |
|---|---|---|---|---|---|---|---|---|
| 120 | 45 sec | 2 | 8 | 2 | 65 min + setups | 3.5% | 92% | 5,302.14 units/day |
| 80 | 30 sec | 1 | 10 | 1 | 40 min + setups | 2.0% | 95% | 2,681.28 units/day |
| 250 | 90 sec | 3 | 12 | 2 | 100 min + setups | 4.0% | 88% | 12,390.40 units/day |
It estimates how many acceptable units a process can produce within a defined time after accounting for runtime, losses, speed reductions, and rejected output.
Cycle time determines how many production cycles fit into available runtime. Small changes in cycle duration can significantly raise or reduce estimated throughput.
Yes. Setup time consumes production availability. Including it gives a more realistic estimate, especially for short runs, frequent changeovers, or batch-based manufacturing lines.
It adjusts ideal output to match actual operating speed. Use it when equipment rarely runs at theoretical maximum pace for a full shift.
Scrap rate removes unusable units from gross output. Higher scrap directly lowers accepted throughput, even if runtime and machine speed remain unchanged.
Yes. The parallel lines field multiplies output for identical lines running simultaneously. Use average inputs when each line performs similarly.
No. It includes an OEE-like composite efficiency for planning, but it is a simplified estimator, not a full diagnostic manufacturing analytics system.
Export CSV for analysis and recordkeeping. Export PDF for meetings, reports, client sharing, or printed review of assumptions and outcomes.