EV & Battery Manufacturing worked example

Battery Tab Weld Defect Rate at 0.35% target maximum weld defect rate: a worked example

This scenario runs the battery tab weld defect rate calculation on the strong side: 0.35% target maximum weld defect rate, with every other input held at its documented default. a cell, module, or pack line needs to monitor weld defects from vision, pull test, resistance, or electrical inspection

The inputs for this scenario

  • Defective tab/busbar welds: 38 welds (unchanged)
  • Total welds inspected: 12,500 welds (unchanged)
  • Target maximum weld defect rate: 0.35 % (raised for this scenario; the documented default is 0.3)

Working through the calculation

  • Applying the documented formula (Tab weld defect rate = defective welds รท total welds inspected) to the inputs above produces each figure below.
  • At this operating point the engine returns 0.3 % weld defects for tab weld defect rate, the number this scenario is built around.
  • At this operating point the engine returns 0.05 points for weld defect gap to limit.
  • At this operating point the engine returns 38 welds for defective welds.
  • At this operating point the engine returns 12,500 welds for welds inspected.

How this compares with the baseline

  • Against the tool's baseline example, where target maximum weld defect rate sits at 0.3% and the headline result is 0.3 % weld defects, this scenario lands almost exactly on the baseline at 0.3 % weld defects.
  • Use it per shift, per station, or per lot to confirm a tab-welding process is holding inside its defect-rate spec. Treat this as a target state: the delta against the baseline quantifies what the improvement is worth before you commit to chasing it.

Results at a glance

  • Tab weld defect rate: 0.3 % weld defects (headline result)
  • Weld defect gap to limit: 0.05 points
  • Defective welds: 38 welds
  • Welds inspected: 12,500 welds

Run it with your numbers

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

Last reviewed 2026-05-12.