Work out capacity utilisation percentage instantly with clear inputs, formula shown and shareable results.
Utilisation measures actual output against design capacity, the theoretical maximum. Efficiency measures it against effective capacity, which already deducts planned maintenance, changeovers and known constraints. Reporting both separates losses management has accepted from losses still on the table.
Utilisation and efficiency
Utilisation % = actual output x 100 / design capacity; efficiency % = actual output x 100 / effective capacity
No. Running a plant at design capacity leaves no room for variability, so queues and lead times explode. Most operations target 80-90% on non-bottleneck resources.
Design capacity assumes ideal conditions with no changeovers, maintenance, product mix penalties or quality losses. Effective capacity is what the plant can actually sustain.