Specialty Films, Membranes & Barrier Materials worked example

Film Gauge Variation at 68% target gauge-variation acceptance rate: a worked example

This worked example runs the film gauge variation numbers for a tougher week than the baseline: 68% target gauge-variation acceptance rate instead of the typical 95%. Estimate film gauge variation for specialty films, membranes and barrier materials using production-ready inputs so teams can track KPI performance and decide whether corrective action is needed.

The inputs for this scenario

  • Rolls flagged for gauge variation: 8 count (held at the documented default)
  • Total rolls gauged in the lot: 250 count (held at the documented default)
  • Target gauge-variation acceptance rate: 68 % (the input this scenario stresses; the baseline uses 95)

Working through the calculation

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

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 %.
  • Use it after every profiling run or shift audit to decide whether die-bolt or tension adjustments are holding caliper within tolerance. 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

  • Film gauge variation rate: 3.2 % (headline result)
  • Film gauge variation gap to target: 64.8 points
  • Film gauge variation count: 8 count
  • Total film gauge variation population: 250 count

Run it with your numbers

  • To rerun this with your own numbers, open the live Film Gauge Variation calculator, set target gauge-variation acceptance rate to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.