Zerdly

Fleet Productivity Calculator

Fleet productivity is the sustained material-movement rate of a truck fleet.

100% FreeRuns in your browserBasic
How to use this calculator

Enter Values

Enter your values and press Calculate to see results.

Before you rely on this: First-pass guide only. Verify safety-critical or regulated work against the relevant standards, your project requirements and a qualified professional.

How to use this calculator

  1. Enter the number of haul trucks, the payload each carries in tonnes, and the average truck cycle time in minutes (load + haul + dump + return + spot/queue).
  2. Enter mechanical availability and utilisation as percentages to discount for downtime and idle/standby time; read off the fleet productivity in tonnes per hour.
  3. Optionally add the shift or operating hours to get tonnes for the period, and the total fleet cost to get an estimated cost per tonne.

How it works

Fleet productivity is the sustained material-movement rate of a truck fleet. The core formula is trucks x payload x (60 / cycle minutes) x availability x utilisation, giving tonnes per hour. The (60 / cycle minutes) term converts one truck's cycle time into trips per hour, payload turns trips into tonnes, and availability and utilisation (each entered as a percent) discount the theoretical peak for mechanical downtime and operating idle time respectively.

When shift or operating hours are supplied, hourly productivity is multiplied out to a tonnage for the period. Adding the total fleet cost for that period then divides cost by tonnes produced to give an estimated cost per tonne. All results are deterministic arithmetic from your inputs; they assume a steady-state cycle and do not model bunching, queueing at the loader, road-grade changes or weather. Treat them as a planning estimate to be checked against real site production data and OEM specifications.

Worked example

Six-truck haulage fleet, 25-minute cycle. With 6 haul trucks each carrying a 90 t payload, a 25-minute cycle time, 85% mechanical availability and 80% utilisation: trips per hour per truck = 60 / 25 = 2.4; effective trucks = 6 x 0.85 x 0.80 = 4.08; fleet productivity = 4.08 x 90 x 2.4 = 881.28 t/h. Over a 12-hour shift that is 881.28 x 12 = 10,575.36 t. If the fleet costs $45,000 for the shift, cost per tonne = 45,000 / 10,575.36 = $4.26/t.

Common mistakes

  • Double-counting downtime by baking it into the cycle time and then also lowering availability/utilisation — pick one place to account for each loss.
  • Entering availability or utilisation as a fraction (0.85) instead of a percent (85); this tool expects percentages between 0 and 100.
  • Forgetting that cost per tonne needs the shift/operating hours as well as the total cost, so a tonnage for the period can be worked out first.

Frequently asked questions

What is the difference between availability and utilisation?

Mechanical availability is the share of scheduled time the trucks are fit to run (not broken down or in maintenance). Utilisation is the share of that available time they are actually working, rather than idle, waiting or on standby. Multiplying both against the truck count gives the effective number of productive trucks.

Does this include the loader or shovel?

No. This tool sizes the haul-truck fleet's output on its own cycle time. To check whether your loading unit and trucks are balanced, compare this against loader/shovel productivity and a shovel-truck match factor separately, and use the smaller of the loading and hauling rates as the real constraint.

Is the result bank or loose tonnes?

It is whatever your payload figure represents. If you enter the rated tonnes actually carried on the tray, the output is tonnes moved. Convert between bank, loose and tonnes beforehand if your production target is quoted on a different basis.

Related tools

Explore more in Mining, Quarry, Earthworks, Drill & Blast.

Tip: Enter any known values to calculate the remaining results.

All calculations run in your browser. Your inputs are never saved or transmitted.