Ceramic, Tile & Sanitaryware Manufacturing worked example

Crack Defect Cost at 2.52% expected crack defect rate: a worked example

This worked example runs the crack defect cost numbers for a tougher week than the baseline: 2.52% expected crack defect rate instead of the typical 3.5%. Estimate cost exposure from cracked tiles, fired cracks, drying cracks, or cracked sanitaryware pieces.

The inputs for this scenario

  • Tiles or fixtures at risk of cracking: 25,000 pieces (held at the documented default)
  • Cost per cracked tile or fixture: 1.85 $ / piece (held at the documented default)
  • Expected crack defect rate: 2.52 % (the input this scenario stresses; the baseline uses 3.5)
  • Fixed containment, sorting, or root-cause cost: 1,200 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Variable cracked-ware loss = pieces at risk × cost per cracked piece × expected crack defect rate.
  • Expected crack defect cost works out to 2,366 $ crack loss at these inputs, and this is the headline figure for the scenario.
  • Expected crack loss per piece at risk works out to 0.09 $ / piece at these inputs.
  • Variable cracked-ware loss works out to 1,166 $ at these inputs.
  • Fixed crack containment cost works out to 1,200 $ at these inputs.

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 16.08% below the baseline at 2,366 $ 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. A result at this level usually justifies acting on the stressed input before touching anything else, because every other figure in the table is downstream of it.

Results at a glance

  • Expected crack defect cost: 2,366 $ crack loss (headline result)
  • Expected crack loss per piece at risk: 0.09 $ / piece
  • Variable cracked-ware loss: 1,166 $
  • Fixed crack containment cost: 1,200 $

Run it with your numbers

  • To rerun this with your own numbers, open the live Crack Defect Cost calculator, set expected crack defect rate to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.