What counts as a rejected component?

Any pump, sprayer or trigger closure scrapped for a defect such as misfit, clogging, dose error or actuation failure in the run covered by the fed count.

Why block rejects above components fed?

A run cannot reject more parts than it fed, so the entry is a unit or range error. The block asks for both counts from the same station and the same run.

What is a reasonable component loss target?

Set it from the component standard or the supplier agreement. The default 1% target on 10,000 fed components allows 100 rejects, so the walkthrough lot at 140 rejects runs 40 over.

Does the loss rate include components damaged in transit?

Only if they were fed to the station and rejected there. Dents found in the packaging before feed belong to incoming inspection, not to this rate.

Personal Care, Cosmetics & Household Products calculator

Pump and Sprayer Component Loss Calculator

Track pump, sprayer and trigger closure scrap on the assembly or capping station. The rate is judged against the target loss you enter, and the excess rejects show where to act.

What this calculator does

Dispenser component loss rate from rejects and components fed, with allowable and excess rejects against a target.

Formula used

Component loss rate = rejected components ÷ components fed × 100
Allowable rejects = components fed × target component loss ÷ 100
Excess rejects = rejected components − allowable rejects
Gap to target = target component loss − component loss rate (positive means below target)

Inputs explained

Rejected Pump and Sprayer Components: Pumps, sprayers and trigger closures scrapped in the run.
Components Fed: Dispenser components fed to the capping station.
Target Component Loss: Allowed scrap target for these components.

How to use the result

Best suited to tracking dispenser scrap per shift, flagging a supplier lot for review, setting a capping scrap target.
The rate covers one run; several runs are needed to see tooling or lot trends. A high rate can come from incoming quality or the assembly station, and this page cannot separate them.

Common questions

What counts as a rejected component? Any pump, sprayer or trigger closure scrapped for a defect such as misfit, clogging, dose error or actuation failure in the run covered by the fed count.
Why block rejects above components fed? A run cannot reject more parts than it fed, so the entry is a unit or range error. The block asks for both counts from the same station and the same run.
What is a reasonable component loss target? Set it from the component standard or the supplier agreement. The default 1% target on 10,000 fed components allows 100 rejects, so the walkthrough lot at 140 rejects runs 40 over.
Does the loss rate include components damaged in transit? Only if they were fed to the station and rejected there. Dents found in the packaging before feed belong to incoming inspection, not to this rate.

Last reviewed 2026-10-01.