Fastener Manufacturing & Thread Rolling worked example

Washer Assembly Rate at 110% target washer assembly rate: a worked example

What does the result look like when target washer assembly rate reaches 110%? The full calculation is worked below with real intermediate numbers. Use it when monitoring washer feed, washer presence, spin-on, or captive assembly performance before finished fasteners move to packaging.

The inputs for this scenario

  • Fasteners with washer correctly assembled: 990 pieces (unchanged)
  • Total washer assembly attempts checked: 1,000 pieces (unchanged)
  • Target washer assembly rate: 110 % (raised for this scenario; the documented default is 99.5)

Working through the calculation

  • Applying the documented formula (Washer assembly rate = correctly assembled washer fasteners ÷ total attempts checked) to the inputs above produces each figure below.
  • At this operating point the engine returns 99 % for washer assembly success rate, the number this scenario is built around.
  • At this operating point the engine returns 11 points for gap to washer target.
  • At this operating point the engine returns 990 count for correct assemblies.
  • At this operating point the engine returns 1,000 count for attempts checked.

How this compares with the baseline

  • Against the tool's baseline example, where target washer assembly rate sits at 99.5% and the headline result is 99 %, this scenario lands almost exactly on the baseline at 99 %.
  • A figure at this level is achievable when target washer assembly rate is genuinely sustained, not just peaked for a shift. It's only as good as the sample — a small or non-random inspection check won't reveal an intermittent feeder fault hiding in the unchecked population.

Results at a glance

  • Washer assembly success rate: 99 % (headline result)
  • Gap to washer target: 11 points
  • Correct assemblies: 990 count
  • Attempts checked: 1,000 count

Run it with your numbers

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

Last reviewed 2026-05-12.