Glass Container & Bottle Manufacturing worked example

Defect Inspection Rate at 1% target defect rate: a worked example

Here is what the math looks like when conditions slip. We hold every other input steady and drop target defect rate to 1%, then walk the calculation through step by step. Calculate inspection defect rate for glass bottles, jars, and containers using rejected containers, inspected containers, and the target defect rate.

The inputs for this scenario

  • Rejected containers at inspection: 420 containers (held at the documented default)
  • Inspected containers: 52,000 containers (held at the documented default)
  • Target defect rate: 1 % (the input this scenario stresses; the baseline uses 0.7)

Working through the calculation

  • The calculation starts from the formula this tool documents: Defect inspection rate = rejected containers at inspection ÷ inspected containers × 100.
  • Inspection defect rate works out to 0.81 % at these inputs, and this is the headline figure for the scenario.
  • Defect-rate gap to target works out to 0.19 points at these inputs.
  • Rejected containers at inspection works out to 420 count at these inputs.
  • Inspected containers works out to 52,000 count at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where target defect rate sits at 0.7% and the headline result is 0.81 %, this scenario lands almost exactly on the baseline at 0.81 %.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to target defect rate, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. It only counts defects the inspection machines actually detect — undetected hairline checks or faults below the camera threshold pass through, so this rate understates true quality escapes.

Results at a glance

  • Inspection defect rate: 0.81 % (headline result)
  • Defect-rate gap to target: 0.19 points
  • Rejected containers at inspection: 420 count
  • Inspected containers: 52,000 count

Run it with your numbers

  • To rerun this with your own numbers, open the live Defect Inspection Rate calculator, set target defect rate to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.