Scrap & Rework Cost Calculator
Put a dollar figure on the parts you throw away and the parts you fix twice, and see what a realistic reduction would return. Your numbers stay in your browser.
Annual scrap + rework cost
$0
How this is calculated
Scrap cost is the value of units discarded; rework cost is the extra spend to bring failing units back to spec. Both scale with your volume and the rates you set.
The reduction slider applies a single percentage against the combined total to project savings from an improvement effort.
What to keep honest here
- Scrap is valued at fully loaded cost. A scrapped unit has already consumed material, machine time, labor, and overhead, so it is valued at the full loaded cost per unit, not just raw material. This is the honest number and it is usually larger than people expect.
- Rework has its own price. Rework cost per unit should capture the added labor, handling, and retest to recover a unit, on top of the original build.
- Rates should reflect reality. Use measured scrap and rework rates, not targets. If the same unit is reworked more than once, your effective rate is higher than a first-pass count suggests.
- Reduction is an assumption. The reduction slider is your expectation, not a guarantee. Use a figure you can defend from a specific improvement.
Scrap and rework are the shop-floor share of poor quality, and they often ride alongside lost machine time. Roll them into the bigger picture with the cost of quality calculator, trace them upstream with the first pass yield and RTY calculator, and value the lost hours with the downtime cost calculator. For the improvement system around them, see lean manufacturing.
Stop paying for the same part twice
Harmony connects your machines, quality checks, and paperwork into one real-time operational layer, no rip-and-replace, so the conditions that drive scrap and rework surface early enough to act on. Read the CLS case study.
Book a Demo →