Blow Molding & Hollow Plastic Products worked example

Defect Cost at 110% defect cost allocation share: a worked example in blow molding & hollow plastic products

What does the result look like when defect cost allocation share reaches 110%? The full calculation is worked below with real intermediate numbers. a blow molding plant needs to quantify the cost impact of rejected containers, sorting, rework, or customer containment

The inputs for this scenario

  • Defective bottles or containers: 850 units (unchanged)
  • Average cost per defective container: 0.64 $ / unit (unchanged)
  • Defect cost allocation share: 110 % (raised for this scenario; the documented default is 100)
  • Fixed containment and sorting cost: 1,400 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Allocated variable defect cost = defective bottles or containers × average cost per defective container × defect cost allocation share) to the inputs above produces each figure below.
  • At this operating point the engine returns 1,998 $ for total blow molding defect cost, the number this scenario is built around.
  • At this operating point the engine returns 2.35 $ / defect for average cost per defective container.
  • At this operating point the engine returns 598 $ for allocated variable defect cost.
  • At this operating point the engine returns 1,400 $ for fixed containment and sorting cost.

How this compares with the baseline

  • Against the tool's baseline example, where defect cost allocation share sits at 100% and the headline result is 1,944 $, this scenario comes in 2.8% above the baseline at 1,998 $.
  • A figure at this level is achievable when defect cost allocation share is genuinely sustained, not just peaked for a shift. The cost per defective container is only as good as your loaded cost data; using bare resin cost instead of fully loaded cost understates the real loss.

Results at a glance

  • Total blow molding defect cost: 1,998 $ (headline result)
  • Average cost per defective container: 2.35 $ / defect
  • Allocated variable defect cost: 598 $
  • Fixed containment and sorting cost: 1,400 $

Run it with your numbers

  • Every input above is editable in the live Defect Cost calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.