Commercial Vehicle, Bus & Coach Manufacturing worked example

Quality Gate Defect Rate at 3.6% target quality gate defect rate: a worked example

This worked example runs the quality gate defect rate numbers for a tougher week than the baseline: 3.6% target quality gate defect rate instead of the typical 5%. Calculate defect rate at a commercial vehicle, bus, or coach quality gate.

The inputs for this scenario

  • Defects found at the quality gate: 14 units (held at the documented default)
  • Vehicles inspected at the gate: 120 units (held at the documented default)
  • Target quality gate defect rate: 3.6 % (the input this scenario stresses; the baseline uses 5)

Working through the calculation

  • The calculation starts from the formula this tool documents: Quality Gate Defect Rate = defects found at the quality gate รท vehicles inspected at the gate.
  • Rate works out to 11.67 % at these inputs, and this is the headline figure for the scenario.
  • quality gate defect rate gap to target works out to -8.07 points at these inputs.
  • Affected count works out to 14 count at these inputs.
  • Total count works out to 120 count at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where target quality gate defect rate sits at 5% and the headline result is 11.67 %, this scenario lands almost exactly on the baseline at 11.67 %.
  • Use it at each end-of-line or in-process gate to track first-time quality per shift, per gate, or per body type and to trigger containment when the rate breaches target. 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

  • Rate: 11.67 % (headline result)
  • quality gate defect rate gap to target: -8.07 points
  • Affected count: 14 count
  • Total count: 120 count

Run it with your numbers

  • To rerun this with your own numbers, open the live Quality Gate Defect Rate calculator, set target quality gate defect rate to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.