Appliances, HVAC & White Goods Manufacturing worked example

Appliance Defect Rate Calculator at 1.38% target production defect rate: a worked example

Push target production defect rate up to 1.38% and the picture changes. This example computes every intermediate figure at that operating point. a quality manager needs to monitor defect rate for an appliance or HVAC production line

The inputs for this scenario

  • Defective appliance or HVAC units found: 86 units (unchanged)
  • Total units inspected or end-of-line tested: 5,200 units (unchanged)
  • Target production defect rate: 1.38 % (raised for this scenario; the documented default is 1.2)

Working through the calculation

  • Applying the documented formula (Production defect rate = defective units ÷ total units inspected or tested × 100) to the inputs above produces each figure below.
  • At this operating point the engine returns 1.65 % for production defect rate, the number this scenario is built around.
  • At this operating point the engine returns -0.27 points for defect-rate gap to target.
  • At this operating point the engine returns 86 units for defective units.
  • At this operating point the engine returns 5,200 units for total units inspected or tested.

How this compares with the baseline

  • Against the tool's baseline example, where target production defect rate sits at 1.2% and the headline result is 1.65 %, this scenario lands almost exactly on the baseline at 1.65 %.
  • It computes the production defect rate as defective units divided by total units inspected times 100, and the gap in percentage points to your target. The value of this scenario is the size of the gap it exposes: that gap, priced out over a year, is the budget you can justify spending to close it.

Results at a glance

  • Production defect rate: 1.65 % (headline result)
  • Defect-rate gap to target: -0.27 points
  • Defective units: 86 units
  • Total units inspected or tested: 5,200 units

Run it with your numbers

  • Every input above is editable in the live Appliance Defect Rate Calculator calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.