Wire Harness, Cable & Electromechanical Assembly worked example

Harness Defect Rate at 68% first-pass yield target for the line: a worked example

Suppose first-pass yield target for the line falls to 68%. This page works the full calculation at that level so you can see exactly which result moves and by how much. Estimate harness defect rate for wire harness, cable and electromechanical assembly using production-ready inputs so teams can track KPI performance and decide whether corrective action is needed.

The inputs for this scenario

  • Harnesses failing inspection or continuity test: 8 count (held at the documented default)
  • Harnesses built and inspected in the run: 250 count (held at the documented default)
  • First-pass yield target for the line: 68 % (the input this scenario stresses; the baseline uses 95)

Working through the calculation

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

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 %.
  • It computes the percent of harnesses that failed inspection out of the total built, plus how far that sits from your yield target. When the numbers land here, the stressed input is the lever to work; the walkthrough above shows exactly how much each output recovers as it climbs back toward the baseline.

Results at a glance

  • Harness defect rate: 3.2 % (headline result)
  • Harness defect rate gap to target: 64.8 points
  • Harness defect rate count: 8 count
  • Total harness defect rate population: 250 count

Run it with your numbers

  • To rerun this with your own numbers, open the live Harness Defect Rate calculator, set first-pass yield target for the line to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.