Wire Drawing & Rod Processing worked example

Rod-To-Wire Yield at 99% target scrap-loss allowance: a worked example

What does the result look like when target scrap-loss allowance reaches 99%? The full calculation is worked below with real intermediate numbers. Use it when rod-to-wire yield 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

  • Scrap and cobble weight lost: 8 units (unchanged)
  • Rod charged into the line: 250 units (unchanged)
  • Target scrap-loss allowance: 99 % (raised for this scenario; the documented default is 95)

Working through the calculation

  • Applying the documented formula (Rod-To-Wire Yield rate = affected amount ÷ 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 scrap-loss allowance 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 scrap-loss allowance is genuinely sustained, not just peaked for a shift. It reports loss against a target but does not tell you the cause — a high loss could be a bad rod lot, a worn die, or a threading error, so pair it with break logs.

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 Rod-To-Wire Yield calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.