Adhesives, Sealants & Industrial Bonding worked example

Bonding Process Risk Score with bond failure severity of 4 1-10: a worked example

Here is what the math looks like when conditions slip. We hold every other input steady and drop bond failure severity to 4 1-10, then walk the calculation through step by step. Score bonding process risk from failure severity, defect occurrence, and detection strength before release.

The inputs for this scenario

  • Bond failure severity: 4 1-10 (the input this scenario stresses; the baseline uses 8)
  • Bond defect occurrence: 5 1-10 (held at the documented default)
  • Detection weakness: 6 1-10 (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Bonding process risk score = severity score × occurrence score × detection score.
  • Bonding process risk score works out to 4.85 score at these inputs, and this is the headline figure for the scenario.
  • Bond failure severity works out to 4 1-10 at these inputs.
  • Bond defect occurrence works out to 5 1-10 at these inputs.
  • Detection weakness works out to 6 1-10 at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where bond failure severity sits at 8 1-10 and the headline result is 6.45 score, this scenario comes in 24.81% below the baseline at 4.85 score.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to bond failure severity, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. The 1-10 ratings are judgment-based, so two engineers can score the same mode differently; the score ranks risk but does not by itself prove a process is safe.

Results at a glance

  • Bonding process risk score: 4.85 score (headline result)
  • Bond failure severity: 4 1-10
  • Bond defect occurrence: 5 1-10
  • Detection weakness: 6 1-10

Run it with your numbers

  • To rerun this with your own numbers, open the live Bonding Process Risk Score calculator, set bond failure severity to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.