Composites, Fiberglass & Advanced Materials worked example

Composite Defect Rate at 3.45% target composite defect rate: a worked example

What does the result look like when target composite defect rate reaches 3.45%? The full calculation is worked below with real intermediate numbers. tracking composite manufacturing defect rate

The inputs for this scenario

  • composite defects found: 11 defects (unchanged)
  • composite parts or features inspected: 240 parts (unchanged)
  • target composite defect rate: 3.45 % (raised for this scenario; the documented default is 3)

Working through the calculation

  • Applying the documented formula (Composite Defect Rate = composite defects found ÷ composite parts or features inspected × 100) to the inputs above produces each figure below.
  • At this operating point the engine returns 4.58 % for composite defect rate, the number this scenario is built around.
  • At this operating point the engine returns -1.13 points for composite defect rate gap to target.
  • At this operating point the engine returns 11 count for composite defects found.
  • At this operating point the engine returns 240 count for composite parts or features inspected.

How this compares with the baseline

  • Against the tool's baseline example, where target composite defect rate sits at 3% and the headline result is 4.58 %, this scenario lands almost exactly on the baseline at 4.58 %.
  • A figure at this level is achievable when target composite defect rate is genuinely sustained, not just peaked for a shift. A rate alone hides defect severity and Pareto — one critical delamination and one cosmetic resin run both count as a single defect, so pair it with a defect-type breakdown before acting.

Results at a glance

  • composite defect rate: 4.58 % (headline result)
  • composite defect rate gap to target: -1.13 points
  • composite defects found: 11 count
  • composite parts or features inspected: 240 count

Run it with your numbers

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

Last reviewed 2026-05-12.