Blow Molding & Hollow Plastic Products worked example

Defect Cost at 72% defect cost allocation share: a worked example in blow molding & hollow plastic products

Suppose defect cost allocation share falls to 72%. This page works the full calculation at that level so you can see exactly which result moves and by how much. Estimate cost of blow molded defects from rejected bottles or containers, average defect cost, allocation share, and fixed containment or sorting costs.

The inputs for this scenario

  • Defective bottles or containers: 850 units (held at the documented default)
  • Average cost per defective container: 0.64 $ / unit (held at the documented default)
  • Defect cost allocation share: 72 % (the input this scenario stresses; the baseline uses 100)
  • Fixed containment and sorting cost: 1,400 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Allocated variable defect cost = defective bottles or containers × average cost per defective container × defect cost allocation share.
  • Total blow molding defect cost works out to 1,792 $ at these inputs, and this is the headline figure for the scenario.
  • Average cost per defective container works out to 2.11 $ / defect at these inputs.
  • Allocated variable defect cost works out to 392 $ at these inputs.
  • Fixed containment and sorting cost works out to 1,400 $ at these inputs.

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 7.84% below the baseline at 1,792 $.
  • It computes total defect cost by allocating a per-unit cost across defective containers and adding fixed containment and sorting cost. When the numbers land here, the stressed input is the lever to work; the walkthrough above shows exactly how much each output recovers as it climbs back toward the baseline.

Results at a glance

  • Total blow molding defect cost: 1,792 $ (headline result)
  • Average cost per defective container: 2.11 $ / defect
  • Allocated variable defect cost: 392 $
  • Fixed containment and sorting cost: 1,400 $

Run it with your numbers

  • To rerun this with your own numbers, open the live Defect Cost calculator, set defect cost allocation share to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.