Aerospace & Defense Manufacturing worked example

Material Substitution Risk with technical impact severity of 25 1-10: a worked example

What does the result look like when technical impact severity reaches 25 1-10? The full calculation is worked below with real intermediate numbers. an engineer or procurement lead needs to evaluate risk before substituting an aerospace material or component

The inputs for this scenario

  • Technical impact severity: 25 1-10 (raised for this scenario; the documented default is 10)
  • Substitution pressure likelihood: 5 1-10 (unchanged)
  • Compliance or performance detection difficulty: 8 1-10 (unchanged)

Working through the calculation

  • Applying the documented formula (Material substitution risk score = severity score × likelihood score × detection difficulty score) to the inputs above produces each figure below.
  • At this operating point the engine returns 13.75 score for material substitution risk score, the number this scenario is built around.
  • At this operating point the engine returns 25 1-10 for technical impact severity.
  • At this operating point the engine returns 5 1-10 for substitution pressure likelihood.
  • At this operating point the engine returns 8 1-10 for compliance or performance detection difficulty.

How this compares with the baseline

  • Against the tool's baseline example, where technical impact severity sits at 10 1-10 and the headline result is 7.75 score, this scenario comes in 77.42% above the baseline at 13.75 score.
  • A figure at this level is achievable when technical impact severity is genuinely sustained, not just peaked for a shift. It ranks risk but does not replace engineering disposition; a low score never authorizes a substitution that violates the drawing or spec without proper sign-off.

Results at a glance

  • Material substitution risk score: 13.75 score (headline result)
  • Technical impact severity: 25 1-10
  • Substitution pressure likelihood: 5 1-10
  • Compliance or performance detection difficulty: 8 1-10

Run it with your numbers

  • Every input above is editable in the live Material Substitution Risk calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.