Run at rate: how to verify capacity before SOP

Theory: demonstrated, not quoted

The quoted capacity comes from the cycle time and an assumed OEE. A run at rate replaces the assumption with evidence: series tooling, gauges, operators and material, for an agreed time.

The OEE needed to meet demand is demand divided by the ideal output at the quoted cycle time. If it is higher than the OEE the line really achieves, the capacity plan does not work.

Step by step

1. Plan the run with the customer: duration, quantity, shift pattern and demand.
2. Run under series conditions and log each stop with its reason and minutes.
3. Enter the results in the run at rate calculator.
4. Read capacity against demand, takt against cycle time and the OEE needed.
5. Act on the top stops from the Pareto, and repeat the run if capacity is below 100 %. Track the line afterwards with the OEE calculator.

Example: assembly cell, 3 shifts

A cell runs 480 minutes with 30 minutes of breaks and 22 minutes of stops (gripper fault, coil change, camera re-teach, waiting for first-off approval). It produces 1 395 parts, 1 378 good: 183.7 good parts per hour. With 5 days × 3 shifts × 7.5 h = 112.5 h per week the capacity is about 20 670 parts against a demand of 19 500, or 106 %. Takt time is 20.8 s against a quoted cycle of 17.5 s, and the OEE needed is 84.3 % against a quoted 85 %. The run passes, but with a margin below 10 %; the gripper fault is the first improvement.

Common mistakes

• Running with the best operators and pre-sorted material.
• Not counting stops shorter than a few minutes.
• Comparing with average demand instead of peak demand.

Frequently asked questions