The Quality Inspection Yield Loss Estimator estimates the portion of processed output that is lost, rejected, or otherwise not counted as acceptable yield. It converts a loss count into a percentage and can also estimate the associated value when a per-unit value is entered.
For inspection stations and quality teams, the result can help separate volume loss from total activity and make repeated loss patterns easier to compare. The calculator does not determine why the loss occurred; classification rules for reject, scrap, rework, or unsuccessful work should be defined consistently before comparing periods.
1. Enter total processed output. Use the full count before subtracting rejects or other defined losses.
2. Enter rejected or lost output. Use the portion of the total that does not meet your accepted-yield definition.
3. Add a unit value if useful. Leave it at zero when you only need the quantity and percentage loss.
4. Review the loss rate and accepted yield. The breakdown also shows the accepted quantity and optional estimated value loss.
Total Processed Output and Lost Output must use the same unit, and Lost Output cannot exceed Total Processed Output. Value per Unit is optional and is used only for the estimated monetary loss.
The result is a direct ratio, not a causal model. Rework that later becomes acceptable should be counted according to the reporting convention you use consistently across periods.
Use the result as an operating estimate for the specific period and definitions represented by the entered inputs.
Compare periods only when units, counting rules, and time definitions are consistent.
Given: 1,000 processed units, 35 rejected units, and an optional unit value of $12.
Calculation: Loss rate = 35 ÷ 1,000 × 100 = 3.50%. Accepted output = 1,000 − 35 = 965 units. Estimated value loss = 35 × $12 = $420.
Result: Yield loss is 3.50%, with 965 accepted units and an estimated $420 of lost value.
Interpretation: The percentage makes periods with different total volumes easier to compare, while the quantity and value show the absolute scale of the loss.
Use the convention that matches your reporting purpose. If rework is treated as a temporary defect but eventually becomes accepted output, document that choice and apply it consistently.
Yes. The loss percentage and accepted quantity still calculate normally; the monetary loss will simply show zero.
That input combination is invalid because the lost amount is defined as part of total processed output. Correct the counts or make sure both values cover the same period and unit.
Not necessarily. Scrap rate usually refers specifically to material or units that cannot be recovered, while yield loss may use a broader definition that includes other rejected or non-accepted output.
Use the loss percentage for normalized comparison and review the absolute lost quantity alongside it. A lower percentage can still represent more lost units when total volume is much larger.