What this calculator does
This calculator converts each station’s nominal rate and expected uptime into an effective rate and identifies the lowest value as the likely capacity constraint. It is a first-pass model; real lines also need accumulation, stop interaction, product mix and quality data.
Enter your figures and select calculate.
Planning estimate: Effective station rate = nominal good-capable rate × expected uptime percentage. The lowest effective rate is the first capacity constraint in this simplified model.
Enter comparable station rates
Use the same unit—normally finished packs per minute—and the rate for the same product and format.
- Do not mix cases, units and individual products
- Use sustained capable rate
- Include manual stations where they constrain flow
Use realistic uptime for each station
A fast machine with frequent stops can constrain the line more than a slower reliable machine. Use measured availability where possible.
- Use representative stop data
- Separate blocked and starved time
- Review changeover and replenishment separately
Confirm the result by observation
The bottleneck can move with product, format and time. Observe queues, starvation and state data during representative production.
- Check accumulation before and after the station
- Record the first recurring constraint
- Recalculate after improvement