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Cycle Time and Production Capacity Calculator
Enter a known cycle time, or a timed run and the cycles completed. Add parts per cycle, machines, shift pattern and planned efficiency to get capacity per hour, shift, day and week. Add weekly demand to see utilization and takt time.
Cycle time and capacity calculator
| Step | Formula | Value |
|---|---|---|
| Effective time per part | CT / (parts per cycle × machines) = 45 / (2 × 1) | 22.5 s |
| Capacity per hour | 3600 / 22.5 × 85% | 136 |
| Capacity per shift | 136 × 7.5 h | 1020 |
| Capacity per day | 1020 × 2 shifts | 2040 |
| Capacity per week | 2040 × 5 days | 10200 |
| Utilization | u = demand / capacity = 9000 / 10200 | 88.24 % |
| Takt time | Takt = 270000 s / 9000 | 30 s |
Formulas used
- Observed cycle time
- CT = run time / cycles completed
- Effective time per part
- CT / (parts per cycle × machines)
- Capacity per hour
- 3600 / time per part × planned efficiency
- Capacity per week
- per hour × hours per shift × shifts per day × days per week
- Utilization
- u = weekly demand / weekly capacity
- Takt time
- Takt = available time per week / weekly demand
Assumptions and limits
- Cycle time is the time between finished cycles of one machine or station, including load and unload.
- Parallel machines run the same part at the same cycle time.
- Planned efficiency scales theoretical capacity to an expected one. A target OEE is a common choice; 100% gives theoretical capacity.
- Available time is hours per shift × shifts × days, with breaks already removed from hours per shift.
- Utilization above 100% means demand exceeds expected capacity. Close to 100%, queues and lead times grow quickly in practice.
Worked example
Example: a two-cavity mould completes 80 cycles in a timed 60-minute run. One machine runs two 7.5-hour shifts, five days a week, at a planned efficiency of 85%. Weekly demand is 9,000 parts.
| Step | Formula | Value |
|---|---|---|
| Observed cycle time | CT = 60 min × 60 / 80 cycles | 45 s |
| Effective time per part | CT / (parts per cycle × machines) = 45 / (2 × 1) | 22.5 s |
| Capacity per hour | 3600 / 22.5 × 85% | 136 |
| Capacity per shift | 136 × 7.5 h | 1020 |
| Capacity per day | 1020 × 2 shifts | 2040 |
| Capacity per week | 2040 × 5 days | 10200 |
| Utilization | u = demand / capacity = 9000 / 10200 | 88.24 % |
| Takt time | Takt = 270000 s / 9000 | 30 s |
Result: Cycle time is 45 s, expected capacity is 10200 parts per week, and demand uses 88.2% of it.
How to measure cycle time and capacity
Measure cycle time, don't assume it
Time a run of many cycles and divide by the number completed. This averages out short stops and load variation that a single stopwatch reading misses. Use the routing or programme time only as a check.
Theoretical vs expected capacity
At 100% efficiency the result is the most the equipment can make if it never stops. Real output is lower because of breakdowns, changeovers, slow cycles and scrap. Using your measured OEE as planned efficiency gives a capacity you can plan against.
Compare with demand
Utilization shows how much of expected capacity the demand uses. Takt time shows the pace demand requires. If time per part is longer than takt, the equipment cannot keep up without more machines, more shifts or a shorter cycle.
When the cycle is too slow
Look at the cycle broken into elements: load, process, unload. Moving load and unload outside the machine cycle, adding a cavity or fixture position, or splitting the work across stations can each shorten time per part. The line balancing calculator helps with the last option.
Common mistakes
- Planning at 100% efficiency. No line runs without stops. Use measured OEE or a realistic target.
- Confusing cycle time with lead time. Cycle time is how often a part comes off; lead time is how long one part spends in the whole process.
- Forgetting parts per cycle. A four-cavity tool makes four parts per cycle. Leaving it at one understates capacity by 75%.
- Counting breaks as available time. Enter hours per shift after breaks, or capacity will be overstated.
- Treating 99% utilization as fine. Near full utilization, small disruptions cause long queues. Leave headroom.
Frequently asked questions
How do you calculate cycle time?
Divide production time by the number of cycles completed in it. 80 cycles in 60 minutes is 3,600 s / 80 = 45 s per cycle.
How do you calculate production capacity?
Divide available time by the time per part, then apply planned efficiency. For one machine making 2 parts every 45 s at 85% efficiency: 3,600 / 22.5 × 0.85 = 136 parts per hour.
What is the difference between cycle time and takt time?
Cycle time is how fast you can make a part. Takt time is how fast demand requires it. Time per part must be at or below takt to meet demand.
Should I use OEE as planned efficiency?
If you measure OEE, it is a good basis because it already includes availability, performance and quality losses. If you don't, start from your actual output divided by theoretical capacity over a recent period.
What utilization should I plan for?
There is no single right number. Higher utilization means less spare capacity to absorb breakdowns and demand spikes, so lead times grow sharply as it nears 100%.
Sources
- Hopp, W. J. and Spearman, M. L., Factory Physics, Waveland Press — capacity, utilization and cycle time.
- Groover, M. P., Automation, Production Systems, and Computer-Integrated Manufacturing, Pearson — production rate and plant capacity.
- Rother, M. and Shook, J., Learning to See, Lean Enterprise Institute — takt time.
Results are computed in your browser from the published formulas named above. They are an engineering aid, not a substitute for the governing standard, your drawing, or your customer's requirements.