Industrial Valves, Actuators & Flow Control calculator
Rework Rate From Leakage Failures Calculator
Measure how many leak-tested valves went to rework and how that rate sits against your target. The allowance and excess rows put the gap into valve counts.
What this calculator does
- Leakage rework rate for a tested lot, the allowance at target and the valves above it.
Formula used
- Leakage rework rate = reworked valves ÷ tested valves × 100
- Gap to target rate = target leakage rework rate − leakage rework rate
- Rework allowance at target = target rate × tested valves ÷ 100
- Rework above allowance = reworked valves − rework allowance at target
Inputs explained
- Valves Reworked After Leakage: Valves sent to rework after a leakage test failure.
- Valves Leak-Tested: Valves that completed the leakage test this period.
- Target Leakage Rework Rate: Rework rate your quality plan allows.
How to use the result
- Best suited to reporting lot leakage performance, setting a rework target, triggering a lapping review.
- The rate counts all leakage rework equally, so a seat lap and a body scrap weigh the same. Valves tested twice for other reasons still count once here.
Current U.S. benchmarks
- The U.S. has 21,668 machinery manufacturing establishments employing about 1,086,146 workers (Census County Business Patterns, 2023).
Common questions
- What counts as leakage rework? Any valve that failed the seat or shell leakage test and went back for lapping, re-machining or seal replacement. Rework that fixes a different defect belongs in a separate metric, so the rate stays comparable across lots.
- Why must reworked valves stay within tested? Reworked valves come out of the tested population, so a count larger than the tested count is impossible. The calculator blocks it instead of printing a rate above 100 percent, because that rate would be a data error.
- What does the allowance row show? How many reworked valves the target still permits at the entered lot size. At a 3% target on 200 valves the allowance is 6, so 7 reworked valves sit 1 above it.
- Is the leakage medium part of the math? No. Liquid leaks are read in drops per minute and gas leaks in bubbles per minute, but the rate counts valves against valves. State the medium because it sets the acceptance criterion the test applies.
Last reviewed 2026-10-01.