Incoming rejection rate calculator form
Use the responsive field grid below. It becomes three columns on large screens, two on medium screens, and one on mobile.
Example data table
Use this reference table to compare lots, review rejection levels, and present supplier quality examples to teams.
| Lot | Received | Inspected | Rejected | Defective Units | Total Defects | Rejection Rate | Status |
|---|---|---|---|---|---|---|---|
| Lot A-104 | 1200 | 320 | 7 | 12 | 19 | 2.19% | Controlled |
| Lot B-227 | 950 | 250 | 11 | 17 | 29 | 4.40% | Watch |
| Lot C-330 | 1600 | 400 | 24 | 41 | 66 | 6.00% | Alert |
| Lot D-514 | 780 | 200 | 3 | 6 | 9 | 1.50% | Controlled |
| Lot E-880 | 1420 | 355 | 18 | 30 | 52 | 5.07% | Critical |
Formula used
- Incoming rejection rate (%) = (Rejected Units ÷ Inspected Units) × 100
- Acceptance rate (%) = (Accepted Units ÷ Inspected Units) × 100
- Inspection coverage (%) = (Inspected Units ÷ Received Units) × 100
- Defective unit rate (%) = (Defective Units ÷ Inspected Units) × 100
- First pass yield (%) = ((Inspected Units − Defective Units) ÷ Inspected Units) × 100
- DPU = Total Defects ÷ Inspected Units
- DPMO = (Total Defects ÷ (Inspected Units × Opportunities per Unit)) × 1,000,000
- Reject PPM = (Rejected Units ÷ Inspected Units) × 1,000,000
- Weighted severity points = (Critical × 10) + (Major × 5) + (Minor × 1)
- Weighted defect index = Weighted Severity Points ÷ Inspected Units
- Estimated rejection cost = Rejected Units × Cost per Rejected Unit
- Gap to target (%) = Actual Rejection Rate − Target Maximum Rejection Rate
How to use this calculator
- Enter supplier, batch, inspection date, and the sampling method used for the incoming inspection event.
- Provide received units, inspected units, rejected units, and defective units from your inspection records.
- Add critical, major, and minor defect counts to quantify defect severity and total quality exposure.
- Enter opportunities per unit when you want DPMO for a more advanced quality view.
- Set cost per rejected unit to estimate financial impact from incoming nonconforming material.
- Choose your target maximum rejection rate to compare actual results against internal expectations.
- Submit the form to view the result section under the header and above the calculator form.
- Use the CSV and PDF buttons to share the calculated summary or the example table.
Frequently asked questions
1. What does incoming rejection rate measure?
It measures the percentage of inspected units that fail incoming inspection and are rejected. It helps teams monitor supplier quality, receiving performance, and acceptance consistency.
2. Why use inspected units instead of received units?
Inspected units are the actual review base. Using them keeps the rejection rate tied to the sample or full inspection that generated the decision.
3. Can total defects be higher than defective units?
Yes. One defective unit can contain multiple issues. That is why total defects, DPU, and DPMO often exceed the defective-unit count.
4. What is a good incoming rejection rate?
Targets vary by industry, criticality, and supplier maturity. Many teams prefer very low rejection rates, but acceptable thresholds should match risk tolerance and product requirements.
5. What does the weighted severity score show?
It gives extra importance to critical and major defects. This helps teams avoid treating all defects equally when supplier quality risk is being reviewed.
6. When is DPMO useful here?
DPMO is useful when each unit has multiple defect opportunities. It makes incoming quality performance easier to compare across products with different complexity.
7. Can this calculator support supplier trend reviews?
Yes. Record each lot, export the results, and compare rejection, PPM, and severity over time to spot drift, instability, or improvement.
8. Should I still investigate lots within target?
Yes, especially when critical defects appear. A lot can meet the numeric target and still require action because severity matters as much as rate.