Nonwoven Materials & Technical Textiles worked example

Basis Weight Variation at 68% target out-of-tolerance ceiling: a worked example

This worked example runs the basis weight variation numbers for a tougher week than the baseline: 68% target out-of-tolerance ceiling instead of the typical 95%. Estimate basis weight variation for nonwoven materials and technical textiles using production-ready inputs so teams can track KPI performance and decide whether corrective action is needed.

The inputs for this scenario

  • Rolls outside basis-weight tolerance: 8 count (held at the documented default)
  • Total rolls measured in run: 250 count (held at the documented default)
  • Target out-of-tolerance ceiling: 68 % (the input this scenario stresses; the baseline uses 95)

Working through the calculation

  • The calculation starts from the formula this tool documents: Basis weight variation rate = basis weight variation count ÷ total basis weight variation population × 100.
  • Basis weight variation rate works out to 3.2 % at these inputs, and this is the headline figure for the scenario.
  • Basis weight variation gap to target works out to 64.8 points at these inputs.
  • Basis weight variation count works out to 8 count at these inputs.
  • Total basis weight variation population works out to 250 count at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where target out-of-tolerance ceiling sits at 95% and the headline result is 3.2 %, this scenario lands almost exactly on the baseline at 3.2 %.
  • Use it at end-of-run or end-of-shift to grade web-forming consistency and decide whether the process is in control. 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

  • Basis weight variation rate: 3.2 % (headline result)
  • Basis weight variation gap to target: 64.8 points
  • Basis weight variation count: 8 count
  • Total basis weight variation population: 250 count

Run it with your numbers

  • To rerun this with your own numbers, open the live Basis Weight Variation calculator, set target out-of-tolerance ceiling to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.