Ceramic, Tile & Sanitaryware Manufacturing worked example

Crack Defect Cost at 4.02% expected crack defect rate: a worked example

This scenario runs the crack defect cost calculation on the strong side: 4.02% expected crack defect rate, with every other input held at its documented default. a ceramic quality team is estimating the cost impact of cracks found after drying, firing, inspection, or packaging

The inputs for this scenario

  • Tiles or fixtures at risk of cracking: 25,000 pieces (unchanged)
  • Cost per cracked tile or fixture: 1.85 $ / piece (unchanged)
  • Expected crack defect rate: 4.02 % (raised for this scenario; the documented default is 3.5)
  • Fixed containment, sorting, or root-cause cost: 1,200 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Variable cracked-ware loss = pieces at risk × cost per cracked piece × expected crack defect rate) to the inputs above produces each figure below.
  • At this operating point the engine returns 3,059 $ crack loss for expected crack defect cost, the number this scenario is built around.
  • At this operating point the engine returns 0.12 $ / piece for expected crack loss per piece at risk.
  • At this operating point the engine returns 1,859 $ for variable cracked-ware loss.
  • At this operating point the engine returns 1,200 $ for fixed crack containment cost.

How this compares with the baseline

  • Against the tool's baseline example, where expected crack defect rate sits at 3.5% and the headline result is 2,819 $ crack loss, this scenario comes in 8.53% above the baseline at 3,059 $ crack loss.
  • Use it during a cracking excursion, when scoping a corrective-action project, or when comparing the cost of a defect against the cost of fixing its cause. Treat this as a target state: the delta against the baseline quantifies what the improvement is worth before you commit to chasing it.

Results at a glance

  • Expected crack defect cost: 3,059 $ crack loss (headline result)
  • Expected crack loss per piece at risk: 0.12 $ / piece
  • Variable cracked-ware loss: 1,859 $
  • Fixed crack containment cost: 1,200 $

Run it with your numbers

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

Last reviewed 2026-05-12.