A vest on a charger is not a vest on the floor. Fleet size is players per game times how many arenas run at once, plus the share that is always charging, in repair, or missing a shoulder strap — and it rounds up, because you cannot buy 41.4 packs.
18 players across two arenas with a 15% spare share is 42 vests, not the 36 that a demand-only count suggests.
The example
Three build-outs, each with a game size, a number of arenas running concurrently, and a spare allowance.
| A | B | C | D | E | |
|---|---|---|---|---|---|
| 1 | Build | Players/game | Arenas | Spare | Vests |
| 2 | Two-arena FEC | 18 | 2 | 15% | 42 |
| 3 | Three-arena park | 24 | 3 | 20% | 87 |
| 4 | Single mobile rig | 12 | 1 | 25% | 15 |
The formula
Demand, then the gross-up:
How it works
Three decisions, in order:
B2*C2is the number of vests physically in play at the busiest moment. Use the maximum game size you sell, not the average.(1+D2)is the spare share. It covers charging rotation, units out for repair, and the pack a birthday guest drops. 15% is a floor; 25% is normal for a mobile operation.ROUNDUP(...,0)because a vest is a whole unit — and because being one short at peak means turning away a paying group.- Multiply by the unit price for the capital line, and by the annual repair rate for the operating one.
Revisit the spare share after a season of real repair logs. The purchase decision is a guess once; after that it is data.
Try it: interactive demo
Enter the maximum players per game, the arenas running at once, and your spare share.
Variations
Capital cost of the fleet
Multiply the vest count by the unit price to size the purchase order.
Chargers needed
Divide the fleet by the bays on one charging rack and round up.
Pitfalls & errors
Back-to-back sessions do not let you reuse the same vests. If a new group briefs while the last is still playing, both games are concurrent for fleet purposes even though only one arena is active.
Buy in whole charging-rack multiples. A fleet of 42 with 12-bay racks means four racks and six empty bays — six more vests may cost less than the awkwardness.
Do not compute the spare share as a percentage of the fleet you are buying. It is a gross-up on demand: 15% spare means demand/(0.85) if you define it that way, which is a different and larger number. Pick one definition and label the column.
Practice workbook
Frequently asked questions
How big a spare share is right?
Should I count vests for the briefing room?
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