Wire Drawing & Rod Processing worked example

Breakage Loss at 99% target break-free rate: a worked example

Push target break-free rate up to 99% and the picture changes. This example computes every intermediate figure at that operating point. Use it when breakage loss in wire drawing and rod processing needs a clean rate and gap-to-target you can put on a tier board.

The inputs for this scenario

  • Wire breaks in the run: 8 units (unchanged)
  • Total lengths (or coils) drawn: 250 units (unchanged)
  • Target break-free rate: 99 % (raised for this scenario; the documented default is 95)

Working through the calculation

  • Applying the documented formula (Breakage Loss rate = affected amount รท total amount) to the inputs above produces each figure below.
  • At this operating point the engine returns 3.2 % for rate, the number this scenario is built around.
  • At this operating point the engine returns 95.8 points for gap to target.
  • At this operating point the engine returns 8 count for affected count.
  • At this operating point the engine returns 250 count for total count.

How this compares with the baseline

  • Against the tool's baseline example, where target break-free rate sits at 95% and the headline result is 3.2 %, this scenario lands almost exactly on the baseline at 3.2 %.
  • It computes the wire break rate as breaks divided by total lengths drawn, then reports the gap between your target break-free rate and that break rate. The value of this scenario is the size of the gap it exposes: that gap, priced out over a year, is the budget you can justify spending to close it.

Results at a glance

  • Rate: 3.2 % (headline result)
  • Gap to target: 95.8 points
  • Affected count: 8 count
  • Total count: 250 count

Run it with your numbers

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

Last reviewed 2026-05-12.