EV & Battery Manufacturing worked example

Battery Tab Weld Defect Rate at 1% target maximum weld defect rate: a worked example

This worked example runs the battery tab weld defect rate numbers for a tougher week than the baseline: 1% target maximum weld defect rate instead of the typical 0.3%. Calculate tab or busbar weld defect rate from defective welds, inspected welds, and the target defect limit.

The inputs for this scenario

  • Defective tab/busbar welds: 38 welds (held at the documented default)
  • Total welds inspected: 12,500 welds (held at the documented default)
  • Target maximum weld defect rate: 1 % (the input this scenario stresses; the baseline uses 0.3)

Working through the calculation

  • The calculation starts from the formula this tool documents: Tab weld defect rate = defective welds รท total welds inspected.
  • Tab weld defect rate works out to 0.3 % weld defects at these inputs, and this is the headline figure for the scenario.
  • Weld defect gap to limit works out to 0.7 points at these inputs.
  • Defective welds works out to 38 welds at these inputs.
  • Welds inspected works out to 12,500 welds at these inputs.

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. A result at this level usually justifies acting on the stressed input before touching anything else, because every other figure in the table is downstream of it.

Results at a glance

  • Tab weld defect rate: 0.3 % weld defects (headline result)
  • Weld defect gap to limit: 0.7 points
  • Defective welds: 38 welds
  • Welds inspected: 12,500 welds

Run it with your numbers

  • To rerun this with your own numbers, open the live Battery Tab Weld Defect Rate calculator, set target maximum weld defect rate to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.