Calculator Inputs
Enter production volume, rejected units, rework activity, defect opportunities, and cost data. The calculator returns rejection rate, yield, DPMO, PPM, and financial loss indicators.
Example Data Table
Use this sample table to validate your workflow and compare how rework changes final rejection rate and yield.
| Batch | Total Units | Rejected | Reworked | Final Scrap | Initial Rejection Rate | Final Yield |
|---|---|---|---|---|---|---|
| RX-101 | 8,000 | 280 | 90 | 190 | 3.50% | 97.63% |
| RX-102 | 9,500 | 355 | 150 | 205 | 3.74% | 97.84% |
| RX-103 | 10,200 | 510 | 180 | 330 | 5.00% | 96.76% |
| RX-104 | 11,000 | 275 | 120 | 155 | 2.50% | 98.59% |
Formula Used
1) Initial Rejection Rate
Initial Rejection Rate (%) = (Rejected Units ÷ Total Units Produced) × 100
2) Final Scrap Units
Final Scrap Units = Rejected Units − Reworked Units
3) Final Rejection Rate
Final Rejection Rate (%) = (Final Scrap Units ÷ Total Units Produced) × 100
4) First Pass Yield
First Pass Yield (%) = ((Total Units − Rejected Units) ÷ Total Units) × 100
5) Final Yield
Final Yield (%) = ((Total Units − Final Scrap Units) ÷ Total Units) × 100
6) Rework Recovery Rate
Rework Recovery Rate (%) = (Reworked Units ÷ Rejected Units) × 100
7) Defects Per Unit and DPMO
DPU = Total Defects ÷ Total Units Produced
DPMO = (Total Defects ÷ (Total Units × Opportunities Per Unit)) × 1,000,000
8) Cost of Poor Quality
Scrap Cost = Final Scrap Units × Manufacturing Cost Per Unit
Rework Cost = Reworked Units × Rework Cost Per Unit
Total Quality Loss = Scrap Cost + Rework Cost + Return Handling Cost
How to Use This Calculator
- Enter the batch name and shift for reporting clarity.
- Input total units produced for the selected production period.
- Enter rejected units found during inspection or testing.
- Add reworked units that were successfully recovered.
- Enter returned units if field failures or customer returns exist.
- Provide total defects and opportunities per unit for DPMO.
- Fill in cost and selling price fields for loss analysis.
- Click the calculate button to view results above the form.
- Use the CSV or PDF buttons to export the current report.
FAQs
1) What does rejection rate measure?
It measures the share of produced units that fail quality standards. A higher rejection rate usually points to process instability, equipment issues, operator mistakes, or material quality problems.
2) Why track both initial and final rejection rates?
Initial rejection rate shows inspection failure at first pass. Final rejection rate shows what remains unrecoverable after rework. Together they reveal true process performance and rework effectiveness.
3) How is rework different from scrap?
Rework covers failed units that can be repaired and released later. Scrap covers failed units with no economic recovery path. Separating them helps estimate both operational loss and salvage potential.
4) What is a good manufacturing rejection rate?
The answer depends on product complexity, tolerances, and industry standards. Many stable processes target very low single-digit rejection rates, but exact limits should match your quality plan and customer requirements.
5) Why is DPMO included here?
DPMO normalizes quality performance by defect opportunities. It helps compare products or lines with different complexity levels and supports Six Sigma style monitoring across large production volumes.
6) Can customer returns affect rejection analysis?
Yes. Returns show defects that escaped internal inspection. Adding them helps quantify hidden quality costs, reverse logistics burden, and the downstream effect of weak detection or containment.
7) What is total quality loss?
It is the combined cost of scrap, rework, and return handling. This value helps production teams prioritize corrective action based on financial impact rather than defect counts alone.
8) How often should this calculator be used?
Use it daily, per shift, per batch, or weekly. Frequent measurement helps detect changes early, supports root cause analysis, and gives managers faster feedback on corrective actions.