Measure defects, yield, and process variation with confidence. Turn inspection data into clear actions for stronger quality performance outcomes today.
| Batch | Produced | Inspected | Defective Units | Total Defects | Reworked | Scrapped | Opportunities |
|---|---|---|---|---|---|---|---|
| Batch A | 12000 | 10000 | 280 | 425 | 150 | 55 | 6 |
| Batch B | 8600 | 8600 | 122 | 190 | 81 | 18 | 4 |
| Batch C | 15000 | 12000 | 410 | 660 | 235 | 74 | 7 |
Defect Rate (%) = (Defective Units / Units Inspected) × 100
Defects per Unit = Total Defects / Units Inspected
Defects per Opportunity = Total Defects / (Units Inspected × Opportunities per Unit)
DPMO = Defects per Opportunity × 1,000,000
First Pass Yield (%) = ((Units Inspected − Defective Units) / Units Inspected) × 100
Throughput Yield (%) = ((Units Inspected − Scrapped Units) / Units Inspected) × 100
Total Quality Loss = Inspection Cost + Rework Cost + Scrap Cost
Severity Index (%) = ((Reworked Units + 2 × Scrapped Units) / Units Inspected) × 100
These formulas help compare batches, estimate process loss, and reveal whether defects mostly drive rework, scrap, or hidden cost pressure.
Enter the batch name first for easy reporting. Add produced and inspected units so the analyzer can distinguish total output from checked output.
Fill in defective units, total defect count, reworked units, and scrapped units. Then provide sample size and defect opportunities per unit.
Add inspection, rework, and scrap costs to estimate financial impact. Press the submit button to show results above the form.
Use the example data button if you want a ready-made scenario. Download CSV for spreadsheets or PDF for quick sharing.
This calculator goes beyond one defect percentage. It combines defect density, DPMO, yield, rework burden, scrap exposure, and cost impact in one report. That broader view helps quality teams spot whether process loss is driven by frequency, severity, or poor recovery.
It also supports practical decision-making. A batch can show an acceptable yield but still hide high rework cost or too many defects per opportunity. By reading these metrics together, teams can set better thresholds, prioritize root-cause analysis, and compare production runs with more confidence.
DPMO estimates how many defects would appear in one million opportunities. It normalizes defect performance across products with different complexity levels.
One unit may contain multiple defects. Tracking both values shows how widespread defects are and how concentrated they are inside failing units.
First pass yield shows the share of inspected units that passed without defect. It reflects how well the process performs before correction.
Rework consumes time and labor, while scrap destroys material value. Splitting them highlights whether recovery is possible or losses are permanent.
Yes. The analyzer uses your sample and inspection inputs to estimate full-batch defect impact. It is useful for quick planning and early control checks.
The severity index weights scrapped units more heavily than reworked units. It creates a simple signal for how damaging the defect outcome is.
Use CSV for deeper analysis in spreadsheets. Use PDF when sharing summary results with managers, auditors, suppliers, or production meetings.
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.