Sheet Metal Stamping & Press Lines worked example

Inspection Sampling at 65% sampling coverage rate: a worked example in sheet metal stamping & press lines

Here is what the math looks like when conditions slip. We hold every other input steady and drop sampling coverage rate to 65%, then walk the calculation through step by step. Inspection Sampling throughput is the effective rate at which a stamping line's quality checks clear parts per hour once you apply the sampling coverage you actually maintain.

The inputs for this scenario

  • Parts checked in the run: 1,200 units (held at the documented default)
  • Inspection window duration: 8 hr (held at the documented default)
  • Sampling coverage rate: 65 % (the input this scenario stresses; the baseline uses 90)

Working through the calculation

  • The calculation starts from the formula this tool documents: Raw inspection sampling = completed output รท runtime.
  • Effective throughput works out to 97.5 units at these inputs, and this is the headline figure for the scenario.
  • Raw throughput works out to 150 units at these inputs.
  • Efficiency works out to 65 % at these inputs.
  • Runtime works out to 8 hr at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where sampling coverage rate sits at 90% and the headline result is 135 units, this scenario comes in 27.78% below the baseline at 97.5 units.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to sampling coverage rate, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. It measures inspection rate, not statistical confidence; a rate that looks adequate can still miss defects if the sampling isn't randomized or the AQL plan is wrong for the lot risk.

Results at a glance

  • Effective throughput: 97.5 units (headline result)
  • Raw throughput: 150 units
  • Efficiency: 65 %
  • Runtime: 8 hr

Run it with your numbers

  • To rerun this with your own numbers, open the live Inspection Sampling calculator, set sampling coverage rate to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.