Fastening, Torque & Joint Assembly worked example

Torque Audit Sample Size at 98% auditor or audit-station availability: a worked example

What does the result look like when auditor or audit-station availability reaches 98%? The full calculation is worked below with real intermediate numbers. Use it before committing a torque audit plan for critical screws, bolts, nuts, or assembled joints on a production shift.

The inputs for this scenario

  • Torque check points per audit round: 24 checks / round (unchanged)
  • Planned torque audit rounds: 6 rounds (unchanged)
  • Auditor or audit-station availability: 98 % (raised for this scenario; the documented default is 85)
  • Valid first-pass torque checks: 96 % (unchanged)

Working through the calculation

  • Applying the documented formula (Gross torque audit checks = torque check points per round × planned audit rounds) to the inputs above produces each figure below.
  • At this operating point the engine returns 135 units for good output capacity, the number this scenario is built around.
  • At this operating point the engine returns 144 units for gross planned torque checks.
  • At this operating point the engine returns 2.88 units for audit availability loss.
  • At this operating point the engine returns 5.64 units for retest or invalid-check allowance.

How this compares with the baseline

  • Against the tool's baseline example, where auditor or audit-station availability sits at 85% and the headline result is 118 units, this scenario comes in 15.29% above the baseline at 135 units.
  • A figure at this level is achievable when auditor or audit-station availability is genuinely sustained, not just peaked for a shift. It assumes the availability and valid-check percentages are stable; a single shift with a long station outage or a fixture problem can make actual usable checks fall well below the modeled number.

Results at a glance

  • Good output capacity: 135 units (headline result)
  • Gross planned torque checks: 144 units
  • Audit availability loss: 2.88 units
  • Retest or invalid-check allowance: 5.64 units

Run it with your numbers

  • Every input above is editable in the live Torque Audit Sample Size calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.