Industrial Valves, Actuators & Flow Control worked example

Rework Rate from Leakage Failures at 2.16% target leakage rework rate: a worked example

Here is what the math looks like when conditions slip. We hold every other input steady and drop target leakage rework rate to 2.16%, then walk the calculation through step by step. Calculate your valve rework rate caused by seat or shell leakage test failures and measure the gap to your quality target. Helps identify whether lapping, re-machining, or seal replacement processes need improvement.

The inputs for this scenario

  • Valves reworked after failing seat or shell leakage test: 7 valves (held at the documented default)
  • Total valves seat/shell leak-tested this period: 200 valves (held at the documented default)
  • Target leakage 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: Leakage rework rate = reworked valves / total valves tested x 100.
  • Leakage rework rate works out to 3.5 % at these inputs, and this is the headline figure for the scenario.
  • Gap to target rework rate works out to -1.34 points at these inputs.
  • Valves reworked (leakage failures) works out to 7 count at these inputs.
  • Total valves tested works out to 200 count at these inputs.

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 %.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to target leakage rework rate, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. 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: -1.34 points
  • Valves reworked (leakage failures): 7 count
  • Total valves tested: 200 count

Run it with your numbers

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

Last reviewed 2026-05-12.