Track scrap percentage and rework impact across runs. See yield, units, and loss in money. Make faster improvements using consistent shop-floor data every day.
| Period | Produced | Scrap | Rework | Scrap % | FPY % | Total Loss |
|---|---|---|---|---|---|---|
| Shift A | 12,500 | 310 | 140 | 2.48% | 96.40% | PKR 1,275,000.00 |
| Shift B | 10,800 | 255 | 90 | 2.36% | 97.00% | PKR 992,500.00 |
| Shift C | 9,950 | 410 | 120 | 4.12% | 94.67% | PKR 1,485,000.00 |
Scrap percentage measures rejected units against total output for a period. A move from 2.0% to 3.0% equals 10 extra scrap units per 1,000 produced, quickly eroding margin. Track by shift and product family, then compare against the same material lot and setup conditions. Use consistent definitions to prevent reporting differences across teams.
First pass yield (FPY) shows how much output passes inspection without rework. When FPY drops, WIP grows and delivery risk rises even if scrap stays flat. Example: 10,000 units with 250 scrap and 150 rework yields 96.00% FPY, yet rework still consumes capacity. Monitoring FPY alongside scrap exposes constraints earlier.
Unit cost converts physical losses into financial impact for reviews. Scrap cost combines lost unit cost plus disposal or recycling fees. Rework cost captures incremental labor, tooling, and retest effort per unit. If unit cost is 900 and scrap is 300 units, direct scrap loss is 270,000 before disposal. This view supports corrective actions with clear payback.
Aggregate scrap can hide localized issues. Segment results by line, station, supplier lot, or changeover window. A 4.1% scrap spike on one shift may indicate setup variation, worn fixtures, or inspection drift. Keep notes for work orders and root‑cause tags so exports remain traceable during audits and daily reviews.
Set targets based on process capability and recent history. Define escalation rules and review cadence: scrap daily, FPY per shift, and cost weekly. A practical alarm is “scrap% above target for two consecutive shifts” or “FPY below 95% on any SKU.” Export CSV to visualize longer trends and confirm sustained gains and highlight shifts needing immediate containment actions quickly.
Consistent metrics support Kaizen and compliance. Capture period, totals, scrap, rework, and cost inputs the same way each time. Use the PDF export for meetings and corrective action records, and keep the CSV for dashboards. Compare improvements against baseline weeks, confirm stability after staffing rotations, and prioritize projects with the largest recurring loss.
1) What counts as scrap in this calculator?
Scrap is any unit that cannot be economically reworked to meet specification. Count it once, at the point you decide it is a reject, and keep the measurement period consistent.
2) Should rework be included in scrap percentage?
Scrap percentage uses scrap units only. Rework is tracked separately because it still consumes capacity and cost. Use FPY and total loss to see the full impact.
3) What if scrap plus rework equals total produced?
That means no good units were released in that period. The calculator will show 0 good units and 0% FPY. Recheck inputs and confirm the time window matches your production report.
4) How do I estimate rework cost per unit?
Use the average extra labor minutes, retest time, and consumables per reworked unit, then convert to currency. Start with a conservative estimate and refine it using time studies or ERP labor tickets.
5) Which period should I choose for reporting?
Pick the period used by your daily management system. Many teams use shift for operations control and week for trend review. The key is comparing like-for-like periods over time.
6) How can I use CSV and PDF exports in audits?
Attach PDF reports to corrective actions and meeting minutes. Use CSV files for dashboards, control charts, and traceable evidence of sustained improvement. Keep the notes field populated for work orders and root-cause tags.
Important Note: All the Calculators listed in this site are for educational purpose only and we do not guarentee the accuracy of results. Please do consult with other sources as well.