Coffee, Tea, Roasting & Dry Goods Processing worked example
Scrap/Rework Cost at 110% affected product scope: a worked example in coffee, tea, roasting & dry goods processing
What does the result look like when affected product scope reaches 110%? The full calculation is worked below with real intermediate numbers. costing rejected or reworked coffee, tea, and dry goods batches
The inputs for this scenario
- Scrap or rework product weight: 180 lb (unchanged)
- Cost per affected pound: 7.8 $/lb (unchanged)
- Affected product scope (capture factor): 110 % (raised for this scenario; the documented default is 100)
- Rework labor, testing, and disposal adders: 260 $ (unchanged)
Working through the calculation
- Applying the documented formula (Variable scrap/rework cost = scrap or rework product weight × cost per affected pound × affected product scope) to the inputs above produces each figure below.
- At this operating point the engine returns 1,804 $ for total scrap/rework cost, the number this scenario is built around.
- At this operating point the engine returns 10.02 $ / piece for scrap/rework cost per sellable unit.
- At this operating point the engine returns 1,544 $ for variable scrap/rework cost.
- At this operating point the engine returns 260 $ for rework labor, testing, and disposal adders.
How this compares with the baseline
- Against the tool's baseline example, where affected product scope sits at 100% and the headline result is 1,664 $, this scenario comes in 8.44% above the baseline at 1,804 $.
- A figure at this level is achievable when affected product scope is genuinely sustained, not just peaked for a shift. It captures direct costs but not the downstream value of lost capacity, expedite fees, or customer goodwill, so for a stockout-driving defect the real cost is higher than this figure.
Results at a glance
- total scrap/rework cost: 1,804 $ (headline result)
- scrap/rework cost per sellable unit: 10.02 $ / piece
- variable scrap/rework cost: 1,544 $
- rework labor, testing, and disposal adders: 260 $
Run it with your numbers
- Every input above is editable in the live Scrap/Rework Cost calculator, which recalculates instantly and can be shared with the inputs intact.
Last reviewed 2026-05-12.