Foundry & Forging worked example

Foundry Rework Rate at 2.16% target maximum rework rate: a worked example

This worked example runs the foundry rework rate numbers for a tougher week than the baseline: 2.16% target maximum rework rate instead of the typical 3%. Calculate the rework rate for castings, forgings, molds, cores, heats, or machined cast products.

The inputs for this scenario

  • Reworked castings or forgings: 16 parts (held at the documented default)
  • Total inspected castings or forgings: 420 parts (held at the documented default)
  • Target maximum rework rate: 2.16 % (the input this scenario stresses; the baseline uses 3)

Working through the calculation

  • The calculation starts from the formula this tool documents: Foundry Rework Rate rate = reworked castings or forgings ÷ total inspected output × 100.
  • Foundry Rework Rate rate works out to 3.81 % at these inputs, and this is the headline figure for the scenario.
  • Foundry Rework Rate gap to target works out to -1.65 points at these inputs.
  • Reworked castings or forgings works out to 16 count at these inputs.
  • Total inspected output works out to 420 count at these inputs.

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. 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

  • Foundry Rework Rate rate: 3.81 % (headline result)
  • Foundry Rework Rate gap to target: -1.65 points
  • Reworked castings or forgings: 16 count
  • Total inspected output: 420 count

Run it with your numbers

  • To rerun this with your own numbers, open the live Foundry Rework Rate calculator, set target maximum rework rate to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.