Manufacturing Run at Rate Calculator
Calculation Results
How to Calculate Run at Rate in Manufacturing
In the manufacturing sector, particularly within automotive and high-volume production environments, "Run at Rate" is a critical milestone. It validates that a production line or process can physically produce components at the quoted quality and capacity levels within a specified timeframe. This calculator helps production managers, quality engineers, and process planners verify if their lines are meeting customer demand.
What is Run at Rate?
Run at Rate is a standardized audit procedure used to verify that a supplier's actual manufacturing process is capable of producing parts of the required quality at the quoted quantity (capacity). It is often part of the Production Part Approval Process (PPAP) or Advanced Product Quality Planning (APQP).
The calculation focuses on the Net Run Rate, which accounts for good parts produced over the total running time, excluding planned downtime but including unplanned downtime to reflect true capability.
The Run at Rate Formula
To calculate the Run at Rate manually, you use the following logic:
Key metrics derived from this calculation include:
- Good Parts: Total output minus defects.
- Efficiency/Utilization: (Actual Rate / Target Rate) × 100%.
- Scrap Rate: (Defects / Total Produced) × 100%.
Real-World Example
Let's assume an injection molding facility has a target to produce 600 units per hour. They run a full 8-hour shift (480 minutes).
- Total Parts Produced: 4,750 units
- Scrap Parts: 150 units
- Run Duration: 480 minutes (8 hours)
Step 1: Calculate Good Parts
4,750 – 150 = 4,600 Good Parts
Step 2: Calculate Hours
480 minutes / 60 = 8.0 Hours
Step 3: Calculate Actual Hourly Rate
4,600 / 8.0 = 575 Parts Per Hour
Step 4: Determine Efficiency
(575 / 600) * 100 = 95.8%
In this scenario, the manufacturer is running at approximately 96% of the target rate. Depending on the customer's threshold (often 100% is required for pass), this might require process optimization to reduce cycle time.
Why is Run at Rate Important?
- Capacity Verification: Ensures the supplier can meet peak volume demands without overtime or expedited freight.
- Quality Assurance: Verifies that increasing speed does not degrade product quality.
- Constraint Identification: Highlights bottlenecks in the production flow (e.g., machine cycle time vs. operator cycle time).