Industrial Valves, Actuators & Flow Control worked example

Rework Rate from Leakage Failures at 3.45% target leakage rework rate: a worked example

What does the result look like when target leakage rework rate reaches 3.45%? The full calculation is worked below with real intermediate numbers. Use this when tracking rework caused by leakage failures during production testing, reporting quality KPIs, or deciding whether to invest in lapping equipment or tighter machining tolerances.

The inputs for this scenario

  • Valves reworked after failing seat or shell leakage test: 7 valves (unchanged)
  • Total valves seat/shell leak-tested this period: 200 valves (unchanged)
  • Target leakage rework rate: 3.45 % (raised for this scenario; the documented default is 3)

Working through the calculation

  • Applying the documented formula (Leakage rework rate = reworked valves / total valves tested x 100) to the inputs above produces each figure below.
  • At this operating point the engine returns 3.5 % for leakage rework rate, the number this scenario is built around.
  • At this operating point the engine returns -0.05 points for gap to target rework rate.
  • At this operating point the engine returns 7 count for valves reworked (leakage failures).
  • At this operating point the engine returns 200 count for total valves tested.

How this compares with the baseline

  • Against the tool's baseline example, where target leakage rework rate sits at 3% and the headline result is 3.5 %, this scenario lands almost exactly on the baseline at 3.5 %.
  • A figure at this level is achievable when target leakage rework rate is genuinely sustained, not just peaked for a shift. It counts any leakage rework equally, so a single drop-past-the-seat reject weighs the same as a scrapped body casting — segment by failure mode before acting.

Results at a glance

  • Leakage rework rate: 3.5 % (headline result)
  • Gap to target rework rate: -0.05 points
  • Valves reworked (leakage failures): 7 count
  • Total valves tested: 200 count

Run it with your numbers

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

Last reviewed 2026-05-12.