Calculator Inputs
Example Data Table
| Audit Period | Total Checked | Discrepant Units | Discrepancy Rate | Critical | Major | Minor | Rework Cost |
|---|---|---|---|---|---|---|---|
| Week 1 | 1000 | 48 | 4.80% | 5 | 14 | 29 | 2400 |
| Week 2 | 1200 | 42 | 3.50% | 4 | 13 | 25 | 2100 |
| Week 3 | 950 | 39 | 4.11% | 3 | 12 | 24 | 1850 |
Formula Used
Discrepancy Rate = (Discrepant Units ÷ Total Units Checked) × 100
Accuracy Rate = 100 − Discrepancy Rate
Count Variance = Actual Count − Expected Count
Variance % = (Count Variance ÷ Expected Count) × 100
Severity Points = (Critical × Critical Weight) + (Major × Major Weight) + (Minor × Minor Weight)
Severity Index = Severity Points ÷ Total Units Checked
First Pass Yield = ((Total Checked − Discrepant Units) ÷ Total Checked) × 100
DPM = (Discrepant Units ÷ Total Units Checked) × 1,000,000
How to Use This Calculator
- Enter the total units inspected during the review period.
- Add the number of discrepant units found.
- Enter expected and actual counts for count variance analysis.
- Fill in critical, major, and minor discrepancy counts.
- Adjust severity weights if your quality policy uses custom scoring.
- Add rework cost, batches checked, and inspection hours.
- Optionally enter previous period values for trend comparison.
- Click the calculate button to display results above the form.
- Use the CSV and PDF buttons to export the result summary.
Frequently Asked Questions
1. What is a discrepancy rate?
Discrepancy rate shows the percentage of checked units that contain errors, mismatches, or nonconformities. It helps teams measure inspection performance and process reliability over time.
2. Why compare expected and actual counts?
Expected versus actual count reveals inventory, production, or audit variance. It identifies whether shortages, overages, or recording mistakes are causing quality control issues.
3. What do critical, major, and minor discrepancies mean?
These levels classify issue severity. Critical issues affect safety or compliance, major issues affect function or acceptance, and minor issues are less serious but still worth tracking.
4. What is a severity index?
Severity index converts discrepancy categories into a weighted score. It helps you compare audit periods when raw discrepancy counts alone do not show true operational impact.
5. What does first pass yield tell me?
First pass yield measures how many inspected units passed without discrepancy. Higher yield usually indicates stronger process control, lower rework demand, and better consistency.
6. Why track discrepancies per batch and per hour?
These productivity measures show whether issues are concentrated in certain batches or inspection windows. They support staffing decisions, shift reviews, and root cause analysis.
7. When should I use previous period values?
Use prior period data when you want trend context. Comparing current and previous rates shows whether quality performance improved, worsened, or stayed stable.
8. Can this calculator support internal audits and supplier checks?
Yes. It works for internal inspections, incoming quality checks, inventory reconciliation, warehouse audits, supplier reviews, and many discrepancy tracking workflows.