Specialty Films, Membranes & Barrier Materials worked example

Film Gauge Variation at 99% target gauge-variation acceptance rate: a worked example

What does the result look like when target gauge-variation acceptance rate reaches 99%? The full calculation is worked below with real intermediate numbers. Use it when film gauge variation in specialty films, membranes and barrier materials needs a clean rate and gap-to-target you can put on a tier board.

The inputs for this scenario

  • Rolls flagged for gauge variation: 8 count (unchanged)
  • Total rolls gauged in the lot: 250 count (unchanged)
  • Target gauge-variation acceptance rate: 99 % (raised for this scenario; the documented default is 95)

Working through the calculation

  • Applying the documented formula (Film gauge variation rate = film gauge variation count ÷ total film gauge variation population × 100) to the inputs above produces each figure below.
  • At this operating point the engine returns 3.2 % for film gauge variation rate, the number this scenario is built around.
  • At this operating point the engine returns 95.8 points for film gauge variation gap to target.
  • At this operating point the engine returns 8 count for film gauge variation count.
  • At this operating point the engine returns 250 count for total film gauge variation population.

How this compares with the baseline

  • Against the tool's baseline example, where target gauge-variation acceptance rate sits at 95% and the headline result is 3.2 %, this scenario lands almost exactly on the baseline at 3.2 %.
  • A figure at this level is achievable when target gauge-variation acceptance rate is genuinely sustained, not just peaked for a shift. It treats every flagged roll equally and ignores the magnitude of the deviation, so a roll 2% out of band counts the same as one 20% out, which can mask severity.

Results at a glance

  • Film gauge variation rate: 3.2 % (headline result)
  • Film gauge variation gap to target: 95.8 points
  • Film gauge variation count: 8 count
  • Total film gauge variation population: 250 count

Run it with your numbers

  • Every input above is editable in the live Film Gauge Variation calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.