Defect Rate (DR)
Percentage of defective items received or produced out of total items
FORMULA
DR = (Defective Items / Total Items) × 100
Alternate Calculations
PPM
(Defective Items / Total Items) × 1000000By Type
Calculate separately for critical, major, minor defectsWhat is Defect Rate?
Defect Rate measures the percentage of items that fail quality standards, either incoming from suppliers or produced internally. This metric indicates quality control effectiveness and manufacturing process health.
Lower defect rates indicate better quality and reduce rework, returns, and warranty costs. World-class manufacturers target defect rates of 1% or less (Six Sigma targets 3.4 defects per million).
Chart
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5,300total · Week 4Defect Rate
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Sample Data
| week | total | defects | rate |
|---|---|---|---|
| Week 1 | 5,000 | 45 | 0.9 |
| Week 2 | 5,200 | 39 | 0.75 |
| Week 3 | 5,100 | 38 | 0.75 |
| Week 4 | 5,300 | 32 | 0.6 |
Required Data Columns
Total UnitsDefective Units