Wire Harness, Cable & Electromechanical Assembly worked example

Harness Defect Rate at 99% first-pass yield target for the line: a worked example

What does the result look like when first-pass yield target for the line reaches 99%? The full calculation is worked below with real intermediate numbers. Use it when harness defect rate in wire harness, cable and electromechanical assembly needs a clean rate and gap-to-target you can put on a tier board.

The inputs for this scenario

  • Harnesses failing inspection or continuity test: 8 count (unchanged)
  • Harnesses built and inspected in the run: 250 count (unchanged)
  • First-pass yield target for the line: 99 % (raised for this scenario; the documented default is 95)

Working through the calculation

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

How this compares with the baseline

  • Against the tool's baseline example, where first-pass yield target for the line 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 first-pass yield target for the line is genuinely sustained, not just peaked for a shift. A raw defect rate treats every failure equally — a cosmetic label defect and a shorted circuit both count as one, so pair it with a Pareto of defect types before acting.

Results at a glance

  • Harness defect rate: 3.2 % (headline result)
  • Harness defect rate gap to target: 95.8 points
  • Harness defect rate count: 8 count
  • Total harness defect rate population: 250 count

Run it with your numbers

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

Last reviewed 2026-05-12.