AI & Digital Manufacturing Analytics worked example

False Positive Inspection Cost at 59% reviewed alert share: a worked example

Here is what the math looks like when conditions slip. We hold every other input steady and drop reviewed alert share to 59%, then walk the calculation through step by step. Estimate the cost of false positive AI inspection alerts from false rejects, inspection cost per event, review share, and fixed containment cost.

The inputs for this scenario

  • False positive inspection alerts: 1,850 alerts (held at the documented default)
  • Cost per false positive review: 18 $ / alert (held at the documented default)
  • Reviewed alert share: 59 % (the input this scenario stresses; the baseline uses 82)
  • Containment and sorting cost: 9,500 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Reviewed false positive cost = false positive alerts × cost per review × reviewed alert share.
  • False positive inspection cost works out to 29,147 $ false positive cost at these inputs, and this is the headline figure for the scenario.
  • Cost per false positive review works out to 15.76 $ / piece at these inputs.
  • Reviewed false positive cost works out to 19,647 $ at these inputs.
  • Containment and sorting cost works out to 9,500 $ at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where reviewed alert share sits at 82% and the headline result is 36,806 $ false positive cost, this scenario comes in 20.81% below the baseline at 29,147 $ false positive cost.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to reviewed alert share, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. It captures review and containment cost but not the harder-to-quantify damage of scrapping good product or operator trust erosion, so treat it as a floor on the true cost.

Results at a glance

  • False positive inspection cost: 29,147 $ false positive cost (headline result)
  • Cost per false positive review: 15.76 $ / piece
  • Reviewed false positive cost: 19,647 $
  • Containment and sorting cost: 9,500 $

Run it with your numbers

  • To rerun this with your own numbers, open the live False Positive Inspection Cost calculator, set reviewed alert share to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.