Does the cost per rejected part rise with quantity?

It falls. The component value per part stays fixed, so the adders matter less as the rejection count grows. A small distortion batch carries most of the fixed batch and containment cost on few parts.

Is scrapped heat-treated material worthless?

No. Scrap retains material value and often sells to a remelt or recycler, so the component cost here is the value lost over that salvage, not zero. Subtract any salvage credit before you enter the cost.

Why is the limit a separate input?

Because the right limit depends on the batch and the program. The page keeps your limit visible and reports the signed overage, so a passing total and a failing one are read the same way.

Which quench problems show up as distortion?

Aggressive quench media reach the highest hardness but risk distortion and cracking, while an oil quench trades some hardness for lower risk. Track rejection counts by quench route and the cost per route follows from this page.

Bearings, Gears & Power Transmission calculator

Heat Treat Distortion Scrap Cost Calculator

Add the value of scrapped heat-treated components to the fixed batch cost and the containment and rework overhead. The page reports the total, the cost per rejected component, and how far the batch sits from your limit.

What this calculator does

The cost of heat-treat distortion scrap for a batch: component value, fixed batch and containment cost, and the overage against your limit.

Formula used

Scrapped value = scrapped components × cost per scrapped component
Batch and containment adders = fixed batch cost + containment and rework overhead
Total scrap cost = scrapped value + batch and containment adders
Cost per rejected component = total scrap cost ÷ scrapped components
Cost over limit = total scrap cost − scrap cost limit

Inputs explained

Scrapped Heat-Treated Components: Components rejected for distortion or hardness after the heat-treat batch.
Cost per Scrapped Component: Fully absorbed cost of one scrapped component, from job costing.
Fixed Heat-Treat Batch Cost: Batch charge that applies whether or not the lot is scrapped.
Containment and Rework Overhead: Sorting, paperwork and rework cost triggered by the batch.
Scrap Cost Limit: Cost the quality program allows for one heat-treat batch.

How to use the result

Best suited to sizing a distortion-driven rejection, building a cost-of-poor-quality case, justifying a quench or fixturing change.
Does not price late delivery, expedited replacement batches or lost capacity from rework. Scrap retains material value; salvage credit is not netted out of the total.

Current U.S. benchmarks

The U.S. has 21,668 machinery manufacturing establishments employing about 1,086,146 workers (Census County Business Patterns, 2023).

Common questions

Does the cost per rejected part rise with quantity? It falls. The component value per part stays fixed, so the adders matter less as the rejection count grows. A small distortion batch carries most of the fixed batch and containment cost on few parts.
Is scrapped heat-treated material worthless? No. Scrap retains material value and often sells to a remelt or recycler, so the component cost here is the value lost over that salvage, not zero. Subtract any salvage credit before you enter the cost.
Why is the limit a separate input? Because the right limit depends on the batch and the program. The page keeps your limit visible and reports the signed overage, so a passing total and a failing one are read the same way.
Which quench problems show up as distortion? Aggressive quench media reach the highest hardness but risk distortion and cracking, while an oil quench trades some hardness for lower risk. Track rejection counts by quench route and the cost per route follows from this page.

Last reviewed 2026-10-01.