Foundry & Forging worked example

Foundry Rework Rate at 3.45% target maximum rework rate: a worked example

This scenario runs the foundry rework rate calculation on the strong side: 3.45% target maximum rework rate, with every other input held at its documented default. Use it when defects require weld repair, grinding, straightening, heat-treat rework, dimensional correction, or retest.

The inputs for this scenario

  • Reworked castings or forgings: 16 parts (unchanged)
  • Total inspected castings or forgings: 420 parts (unchanged)
  • Target maximum rework rate: 3.45 % (raised for this scenario; the documented default is 3)

Working through the calculation

  • Applying the documented formula (Foundry Rework Rate rate = reworked castings or forgings ÷ total inspected output × 100) to the inputs above produces each figure below.
  • At this operating point the engine returns 3.81 % for foundry rework rate rate, the number this scenario is built around.
  • At this operating point the engine returns -0.36 points for foundry rework rate gap to target.
  • At this operating point the engine returns 16 count for reworked castings or forgings.
  • At this operating point the engine returns 420 count for total inspected output.

How this compares with the baseline

  • Against the tool's baseline example, where target maximum rework rate sits at 3% and the headline result is 3.81 %, this scenario lands almost exactly on the baseline at 3.81 %.
  • Use it at end of shift, lot close, or in a quality review to monitor first-pass yield and trigger corrective action. Treat this as a target state: the delta against the baseline quantifies what the improvement is worth before you commit to chasing it.

Results at a glance

  • Foundry Rework Rate rate: 3.81 % (headline result)
  • Foundry Rework Rate gap to target: -0.36 points
  • Reworked castings or forgings: 16 count
  • Total inspected output: 420 count

Run it with your numbers

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

Last reviewed 2026-05-12.