Eyewear, Lenses & Vision Products worked example

Scratch Defect Cost at 72% defect cost assigned to this scope: a worked example

This worked example runs the scratch defect cost numbers for a tougher week than the baseline: 72% defect cost assigned to this scope instead of the typical 100%. Estimate the cost impact of scratched lenses or finished pairs using defect count, replacement/rework cost, affected share, and fixed containment cost.

The inputs for this scenario

  • Scratched lenses or pairs: 38 defects (held at the documented default)
  • Cost per scratch defect: 42 $ / defect (held at the documented default)
  • Defect cost assigned to this scope: 72 % (the input this scenario stresses; the baseline uses 100)
  • Fixed scratch containment cost: 350 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Variable scratch defect cost = scratched lenses or pairs × cost per scratch defect × assigned defect cost share.
  • Total scratch defect cost works out to 1,499 $ at these inputs, and this is the headline figure for the scenario.
  • Average cost per scratched lens or pair works out to 39.45 $ / defect at these inputs.
  • Variable scratch defect cost works out to 1,149 $ at these inputs.
  • Fixed scratch containment cost works out to 350 $ at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where defect cost assigned to this scope sits at 100% and the headline result is 1,946 $, this scenario comes in 22.96% below the baseline at 1,499 $.
  • Use it when building a cost-of-poor-quality case, prioritizing which defect mode to fix first, or justifying spend on handling, fixturing, or coating-process improvements. 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

  • Total scratch defect cost: 1,499 $ (headline result)
  • Average cost per scratched lens or pair: 39.45 $ / defect
  • Variable scratch defect cost: 1,149 $
  • Fixed scratch containment cost: 350 $

Run it with your numbers

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

Last reviewed 2026-05-12.