Order capacity check calculator
Work out whether a new order fits before the promised date using your own figures. Check the assumptions before you act on the result.
Your figures
Result
- Hours needed
- 22.29 hours
- Hours short
- -3.71 hours
How it is worked out
hours needed = quantity x cycle time (seconds) ÷ parts per cycle ÷ 3600 ÷ efficiency; compare with free machine hours before the due date
hours_needed = quantity*cycle_seconds/parts_per_cycle/3600/(efficiency_percent/100)hours_short = hours_needed-free_machine_hours
What it works out
The order capacity check calculator turns records from the business into a figure for this decision: whether a new order fits before the promised date. Use it when the responsible production supervisor needs a consistent answer for this specific task. The answer uses only the values entered. Record the measurement period beside it.
What you need
| Input | Unit | Where to find it |
|---|---|---|
| Quantity (example: 4,700) | units | Enter quantity using the current job, register or approved business plan. |
| Cycle seconds (example: 28 seconds) | seconds | Read cycle seconds from the job card, shift report, machine log or maintenance register. |
| Parts per cycle (example: 2) | units | Read parts per cycle from the job card, shift report, machine log or maintenance register. |
| Efficiency percent (example: 82 %) | % | Read efficiency percent from the job card, shift report, machine log or maintenance register. |
| Free machine hours (example: 26 hours) | hours | Read free machine hours from the job card, shift report, machine log or maintenance register. |
Use the same item, period and measurement unit for related inputs. If a figure comes from an estimate rather than an actual record, mark it as estimated. Keep your original figures beside the result.
The formula
In plain words, calculate hours short using the measured inputs below. The expressions are shown without hidden rounding so they can be checked by hand.
- hours needed:
hours_needed = quantity*cycle_seconds/parts_per_cycle/3600/(efficiency_percent/100). - hours short:
hours_short = hours_needed-free_machine_hours.
Formula basis from the supplied taxonomy: hours needed = quantity x cycle time (seconds) ÷ parts per cycle ÷ 3600 ÷ efficiency; compare with free machine hours before the due date. The calculation assumes the named inputs describe the same job and accounting period. Keep quantities, rates and measured units consistent.
A worked example
Illustrative example: a distribution business uses the figures in the table above. These are example inputs, not industry averages. For this example, the main figures are quantity: 4,700, cycle seconds: 28 seconds, parts per cycle: 2, efficiency percent: 82 %.
- Hours needed:
quantity*cycle_seconds/parts_per_cycle/3600/(efficiency_percent/100). With the example figures,4700.0 * 28.0 / 2.0 / 3600 / (82.0 / 100)gives 22.29 hours. - Hours short:
hours_needed-free_machine_hours. With the example figures,22.28997 - 26.0gives -3.71 hours.
How to act: Use the result to check it against committed machine time. Write down the input date and the assumption that could move most.
How to read the result
Example bands, change them for your business:
- Comfortable: Your result meets the target for this item or reporting period. Keep the calculation with its source records and check it against committed machine time.
- Watch: The result is close to your action limit, or it changed since the previous calculation. Recheck quantity and cycle seconds using the original records.
- Act: The result breaks a limit already agreed by the manager or owner. Record the difference, name a responsible person, and agree a correction date. For an operational starting point, read [Production delays](/problems/production-delays) and [Production plan to output](/processes/production-plan-to-output). Do not use these example bands as published industry benchmarks.
Copy it into a spreadsheet
Create a sheet with column A for the label and column B for the number or formula. The expressions work in Excel or Google Sheets. Keep input cells editable and result cells protected from typing.
| Cell | Label | Value or formula |
|---|---|---|
| B2 | quantity | 4700.000000 |
| B3 | cycle seconds | 28.000000 |
| B4 | parts per cycle | 2.000000 |
| B5 | efficiency percent | 82.000000 |
| B6 | free machine hours | 26.000000 |
| B8 | hours needed | =((((B2*B3)/B4)/3600)/(B5/100)) |
| B9 | hours short | =(B8-B6) |
For any formula containing a divisor, enter a value above zero. For any monetary output, format the cell in Indian rupees. Do not replace the cells with rounded figures until the final display.
What this calculator leaves out
- A machine may be free in the plan while the operator, tool or drawing is unavailable.
- A single average can hide unusual lots, customers or weeks. Review the underlying entries before making a large decision.
- The formula does not check whether the records are complete. Take cycle times from recent job cards, not machine brochures. Count setup, changeovers, breakdowns and operator breaks separately.
Common mistakes
- Mixing periods. Using quantity from one month with cycle seconds from another produces a number that looks precise but is hard to act on.
- Trusting old figures. Recheck the relevant source record before reusing last month's saved inputs. Compare the result with the actual shift report for at least several runs before setting a promise date.
- Treating an estimate as approval. Record which assumptions were entered by hand. Get the relevant owner, accountant or technician to check unusual values.
A number like this helps only if someone works it out again when things change.
Questions people ask
Where do I find the numbers for order capacity check calculator?
Enter quantity using the current job, register or approved business plan. Read cycle seconds from the job card, shift report, machine log or maintenance register. Keep all inputs from the same period.
Can I use this number to approve a purchase or payment?
Use it as a first check. Use the result to check it against committed machine time. Write down the input date and the assumption that could move most. If the result affects tax, legal duties, workplace safety or a major investment, obtain the appropriate review.
When should I calculate it again?
Recalculate when a meaningful input changes, and at the next regular review of the relevant register. Save the date and the input values so changes can be explained.