Track failures, yields, costs, and maintenance burdens precisely. Prioritize corrective actions using practical shop-floor metrics. Find weak process links before defects multiply and spread.
The calculator uses a three-column grid on large screens, two columns on smaller screens, and one column on mobile.
You can use the first row values directly in the calculator for a quick test.
| Process | Units | Failures | Defective Units | Opps/Unit | Downtime | Repair Time | S | O | D | Cost/Failure |
|---|---|---|---|---|---|---|---|---|---|---|
| Sealing Line A | 1200 | 38 | 29 | 6 | 290 min | 180 min | 8 | 6 | 5 | $42.50 |
| Filling Cell B | 1800 | 22 | 17 | 5 | 140 min | 95 min | 7 | 4 | 4 | $31.00 |
| Packing Station C | 950 | 44 | 33 | 4 | 310 min | 210 min | 9 | 7 | 6 | $55.00 |
| Metric | Formula | Meaning |
|---|---|---|
| Failure Event Rate | Failure Events ÷ Units Inspected × 100 | Shows how often failures occur across inspected output. |
| Defect Rate | Defective Units ÷ Units Inspected × 100 | Measures the share of units that failed requirements. |
| DPU | Failure Events ÷ Units Inspected | Average defects or failures per unit. |
| DPMO | Failure Events ÷ (Units × Opportunities per Unit) × 1,000,000 | Normalizes defects against total process opportunities. |
| Yield | (Units Inspected − Defective Units) ÷ Units Inspected × 100 | Estimates first-pass conformance. |
| Availability | (Operating Time − Downtime) ÷ Operating Time × 100 | Shows usable production time after losses. |
| MTBF | Uptime ÷ Failure Events | Average runtime between recorded failures. |
| MTTR | Repair Time ÷ Failure Events | Average time needed to recover from each failure. |
| RPN | Severity × Occurrence × Detection | Ranks risk using a classic FMEA-style logic. |
| Total Failure Cost | (Failure Events × Cost per Failure) + Scrap + Rework + Containment | Approximates cost of poor quality for the period. |
It combines defect, downtime, reliability, risk, and cost measures in one view. That helps quality teams see whether failures are isolated, recurring, expensive, or likely to threaten delivery performance.
Failure events count every recorded issue. Defective units count the number of affected units. One unit can generate multiple failure events, so the two numbers do not always match.
DPMO needs the total number of defect opportunities. A part with many characteristics, checks, or steps has more chances to fail than a simpler part.
Use your standard FMEA scale. Severity reflects impact, occurrence reflects frequency, and detection reflects how likely controls are to catch the issue before escape.
A high RPN means the failure mode combines serious impact, repeat likelihood, and weak detection. It signals that corrective action should be prioritized and tracked closely.
It is an estimate derived from DPMO. It is useful for benchmarking and trend reviews, but it should not replace a full statistical capability study when precision matters.
Yes. You can map units to cases, tickets, or transactions, and opportunities to required checks or task steps. The logic still works for process quality analysis.
COPQ per unit is the cost of poor quality spread across all inspected output. It helps compare lines or periods with different volumes more fairly.
Important Note: All the Calculators listed in this site are for educational purpose only and we do not guarentee the accuracy of results. Please do consult with other sources as well.