6SQ ToolsWhat Is Run@Rate (Launch Capacity Verification) and How Does It Work?
In automotive manufacturing, launching a new product or process is risky. You may have designed a line that should meet demand, but until you run it continuously at full speed, you won't know if it truly can. That is where Run@Rate comes in—a practical, disciplined method to verify that your production system can sustain the targeted output rate over time.
This article explains what Run@Rate is, how it works, and how you can apply it with a simple illustrative example.
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What It Is
Run@Rate (also called launch capacity verification) is a production validation practice used primarily in the automotive industry during process launch or major changeover. Its purpose is to prove that the manufacturing process can operate at the targeted run rate (the planned number of units per hour or per shift) while maintaining quality and stability over a sustained period.
Unlike a short "first-piece" check, Run@Rate runs the line continuously—often for several hours or shifts—under normal production conditions. It verifies not just that the equipment works, but that the whole system (machines, operators, material flow, tooling, and support) can hold the pace without breakdowns, quality losses, or excessive downtime.
Run@Rate is a key step before full production ramp-up, helping to identify bottlenecks, weak points, and capacity gaps early—when fixes are cheaper and safer.
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How It Works / Steps
Run@Rate follows a structured, data-driven approach. While there is no single universal standard number, the method is consistent across industry practice:
Start with the customer demand and the planned takt time (the pace at which a unit must be produced to meet demand). For example, if demand is 60 units per hour, the takt time is 1 minute per unit.
The run must be long enough to expose issues—typically several hours or a full shift. The goal is to observe steady-state behavior, not just startup.
Operate the line at the specified speed, with normal staffing and material supply. Do not slow down or "cheat" to make the numbers look good.
During the run, record:
- Actual output (units produced)
- Downtime (equipment stops, changeovers, waiting)
- Quality yield (good units / total units started)
- Cycle time vs. takt time
Compare actual output to the theoretical target. If the line falls short, identify the constraint and take corrective action.
Run@Rate is often iterative. After fixing issues, run again to confirm the line now meets the target.
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A Worked Illustrative Example
Example data (illustrative only)
Suppose a new assembly line is designed to run at 50 units per hour (takt = 1.2 minutes). The launch team decides to run Run@Rate for 4 hours under normal conditions.
Step 1: Calculate actual production rate
Actual rate = 178 units / 4 hours = 44.5 units/hour
Step 2: Compare to target
The line is running at 44.5 / 50 = 89% of the targeted rate—below the required capacity.
Step 3: Identify the gap
The 35 minutes of downtime represents lost capacity of about 35 min × (50/60) ≈ 29 units. Even without downtime, the line would have produced 178 + 29 = 207 units, which is above target. So the issue is not speed but reliability.
Step 4: Corrective action
The team fixes the sensor alignment and improves the material feed. A second Run@Rate confirms the line now sustains 50+ units/hour with yield above 98%.
This example shows how Run@Rate separates speed capability from availability—two different problems that require different fixes.
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Common Pitfalls
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Closing
Run@Rate is a powerful, low-cost way to de-risk a launch before full production. By running at the targeted rate over a sustained period and measuring output, downtime, and yield, you turn assumptions about capacity into verified facts. If you are planning a launch or a major process change, consider using a structured Run@Rate worksheet to track your results.
For a ready-made template to record your next Run@Rate study, visit the free tool at:
https://www.6sq.com/tools/runrate/
This article explains what Run@Rate is, how it works, and how you can apply it with a simple illustrative example.
---
What It Is
Run@Rate (also called launch capacity verification) is a production validation practice used primarily in the automotive industry during process launch or major changeover. Its purpose is to prove that the manufacturing process can operate at the targeted run rate (the planned number of units per hour or per shift) while maintaining quality and stability over a sustained period.
Unlike a short "first-piece" check, Run@Rate runs the line continuously—often for several hours or shifts—under normal production conditions. It verifies not just that the equipment works, but that the whole system (machines, operators, material flow, tooling, and support) can hold the pace without breakdowns, quality losses, or excessive downtime.
Run@Rate is a key step before full production ramp-up, helping to identify bottlenecks, weak points, and capacity gaps early—when fixes are cheaper and safer.
---
How It Works / Steps
Run@Rate follows a structured, data-driven approach. While there is no single universal standard number, the method is consistent across industry practice:
- Define the target rate.
Start with the customer demand and the planned takt time (the pace at which a unit must be produced to meet demand). For example, if demand is 60 units per hour, the takt time is 1 minute per unit.
- Set the run duration.
The run must be long enough to expose issues—typically several hours or a full shift. The goal is to observe steady-state behavior, not just startup.
- Run at the targeted rate.
Operate the line at the specified speed, with normal staffing and material supply. Do not slow down or "cheat" to make the numbers look good.
- Measure key outputs.
During the run, record:
- Actual output (units produced)
- Downtime (equipment stops, changeovers, waiting)
- Quality yield (good units / total units started)
- Cycle time vs. takt time
- Calculate capacity and efficiency.
Compare actual output to the theoretical target. If the line falls short, identify the constraint and take corrective action.
- Repeat if necessary.
Run@Rate is often iterative. After fixing issues, run again to confirm the line now meets the target.
---
A Worked Illustrative Example
Example data (illustrative only)
Suppose a new assembly line is designed to run at 50 units per hour (takt = 1.2 minutes). The launch team decides to run Run@Rate for 4 hours under normal conditions.
- Theoretical target output = 50 units/hour × 4 hours = 200 units
- Actual output = 178 good units
- Total downtime = 35 minutes (due to a sensor misalignment and a material feed jam)
Step 1: Calculate actual production rate
Actual rate = 178 units / 4 hours = 44.5 units/hour
Step 2: Compare to target
The line is running at 44.5 / 50 = 89% of the targeted rate—below the required capacity.
Step 3: Identify the gap
The 35 minutes of downtime represents lost capacity of about 35 min × (50/60) ≈ 29 units. Even without downtime, the line would have produced 178 + 29 = 207 units, which is above target. So the issue is not speed but reliability.
Step 4: Corrective action
The team fixes the sensor alignment and improves the material feed. A second Run@Rate confirms the line now sustains 50+ units/hour with yield above 98%.
This example shows how Run@Rate separates speed capability from availability—two different problems that require different fixes.
---
Common Pitfalls
- Running too short. A 30-minute run may miss intermittent failures. Use a duration long enough to represent real production.
- Ignoring yield. Producing 200 units/hour is useless if 30% are defective. Always measure good units, not just total output.
- Slowing down to pass. If you reduce the rate to avoid problems, you are not validating the actual target. Run at the real required speed.
- Not involving operators. Run@Rate is about the whole system, including human factors. Operators must be present and working normally.
- One run is enough. If you make changes, re-run. A single successful run does not guarantee stability.
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Closing
Run@Rate is a powerful, low-cost way to de-risk a launch before full production. By running at the targeted rate over a sustained period and measuring output, downtime, and yield, you turn assumptions about capacity into verified facts. If you are planning a launch or a major process change, consider using a structured Run@Rate worksheet to track your results.
For a ready-made template to record your next Run@Rate study, visit the free tool at:
https://www.6sq.com/tools/runrate/
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