MRO Hangar Check Capacity Calculator
A hangar is limited either by physical bays or by the hands available to work in them. This calculator computes both limits and tells you which one binds, plus how many technicians you need to keep every bay productive at your target turn time.
Your numbers
Average across checks of the same type, including findings.
Certifying and non certifying staff doing direct work.
Share of paid hours booked to work orders.
Your results
Planning model with average inputs. Real capacity also depends on skill mix, stores support, tooling, customer induction timing and findings growth.
Checks per year vs technicians
Sweeps Technicians available from 20 to 200, holding your other inputs fixed.
Capacity model from your labor data
Optional: we can discuss pulling actual hours per check and productivity from your ERP into this model.
Optional. The tool and every export work without this. No spam.
How to use the calculator
Enter the number of bays, the average direct man-hours for the check type and your technician count. Set productive hours per day, direct productivity and the working calendar. The target turn time is the number of working days you commit to in the contract. The result shows annual checks by labor, by bays and the lower of the two.
The formulas
Bay capacity is bays times working days divided by turn time, because each bay is occupied for a full turn time per check. Labor capacity is the productive man-hours available per year divided by man-hours per check. Technicians needed per check come from spreading the man-hours over the target turn time.
- Productive hours per tech per day = hours x productivity
- Bay limit = bays x working days / turn time
- Labor limit = techs x productive hours x working days / man-hours per check
- Techs per check = man-hours / (turn time x productive hours)
Worked example
Three bays, 90 technicians, 6,500 hours per check, 75 percent productivity and a 21 day turn give a bay limit near 43 checks and a labor limit near 62. The hangar is bay constrained, and you would need about 8.2 technicians per day-equivalent per check, meaning roughly 26 technicians to feed three bays. The surplus labor argues for a fourth bay or for shorter turn times to increase throughput.
Common mistakes
Using average man-hours without allowing for findings growth, double counting non-productive roles, and forgetting that turn time inflates when parts or engineering dispositions are late are the most common errors. Test the plan with a pessimistic man-hour figure as well as the average.
Frequently Asked Questions
Does the model include nights and shifts?
Yes if you count them in the hours and technicians. For multiple shifts, enter the total technicians across shifts and the total productive hours per person per day. Bay occupancy is calendar based, so do not double count bays.
How do I get direct man-hours per check?
Take actual booked hours from completed work orders by check type, including non-routine cards, and use the average or a percentile. Using the task card estimate alone understates real demand.
What productivity is realistic?
It varies widely by organisation and by definition. Measure your own booked direct hours against paid attendance, and avoid using a number from a different shop with a different method.
Why does adding technicians stop helping?
Once labor exceeds the bay limit, extra people add cost without adding checks. The chart shows the technician count where labor and bay lines cross.
Netray can build an agent over your work order and labor booking data to show actual hours per check and productivity by hangar bay.
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